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Volkswagen Golf Mk7 Service & Repair Manual: Assembly overview - fuel delivery unit/fuel gauge sender, vehicles with four-wheel drive

This assembly overview covers the 4MOTION Volkswagen Golf Mk7 fuel delivery unit: the fuel pump control unit -J538-, checked via the vehicle diagnostic tester, with its connector needing a firm, confirmed engagement.

Assembly overview - fuel delivery unit/fuel gauge sender, vehicles with four-wheel drive

1 -  Fuel pump control unit -J538-
Check with → Vehicle diagnostic tester
Removing and installing → Chapter
2 -  Electrical connector
For fuel pump control unit -J538-.
Make sure it is engaged properly; pull to check that plug-in connector is correctly engaged
3 -  Electrical connector
For fuel system pressurisation pump -G6-.
Make sure it is engaged properly; pull to check that plug-in connector is correctly engaged
4 -  Electrical connector
For fuel gauge sender -G- and fuel gauge sender 2 -G169-
Make sure it is engaged properly; pull to check that plug-in connector is correctly engaged
5 -  Locking ring
Loosen and tighten with wrench -T10202-.
110 Nm
6 -  Flange
Removing and installing → Chapter
7 -  Seal
Renew after removing
Install dry.
8 -  Fuel gauge sender 2 -G169-
Carry out electrical test → Vehicle diagnostic tester
Removing and installing → Chapter
9 -  Mounting with suction-jet pump
No replacement part available
Welded to fuel tank
Function → Chapter.
10 -  Fuel gauge sender -G-
Carry out electrical test → Vehicle diagnostic tester
Removing and installing.
11 -  Fuel delivery unit
With fuel system pressurisation pump -G6-.
With integrated fuel filter
The fuel filter cannot be renewed individually
Carry out electrical test on fuel pump with → Vehicle diagnostic tester
After installing, fill vehicle with at least 5 litres of fuel.
Removing and installing → Chapter
12 -  Seal
Renew after removing
Install dry.
13 -  Locking ring
Remove and tighten with wrench -T10202-.
110 Nm
14 -  Fuel line
To engine.
Do not kink
To disconnect from flange, press release tab on connection piece
Connect so it engages audibly
Press in again and then pull to check that plug-in connector is correctly engaged

 
     
Installation position of fuel delivery unit
The arrow -3- on the fuel tank must line up with the mark -2- on the sealing flange -1-.
 

Assembly overview - fuel delivery unit/fuel gauge sender, vehicles with four-wheel drive

    Questions & answers

    Assembly overview - fuel delivery unit/fuel gauge sender, vehicles with four-wheel drive — Volkswagen Golf Mk7

    How does the Golf Mk7 4WD fuel delivery unit differ?
    Different shape to fit the 4WD-specific tank. Same functional components.
    Assembly overview - fuel delivery unit/fuel gauge sender, vehicles with front-wheel drive
    1 -  Fuel delivery unit With fuel system pressurisation pump -G6-. With integrated fuel filter; cannot be renewed individually. ...

    Assembly overview - fuel delivery unit/fuel gauge sender, vehicles with auxiliary heater
    1 -  Fuel delivery unit With fuel system pressurisation pump -G6-. With integrated fuel filter; fuel filter cannot be renewed separately ...

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