Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 762
– Partially loosen the cover -1- in the carpet at the separating
line -arrow-.
– Do not separate the cover completely from the carpet so that
later it will be installed correctly.
– Only loosen so far that the cover can be folded up.
– Fold up the cover in the direction of the -arrow-.
Golf and Golf Wagon:
– Remove the rear bench seat. Refer to ⇒ Body Interior; Rep.
Gr. 72 ; Rear Seats; Bench Seat / Single Seats, Removing
and Installing .
Continuation for All Vehicles:
– Unclip the sealing flange cover -1- at the tabs -arrows- using
the -3409- .
– Unclip the grommet -1- downward out of the cover -2-.
– Guide the cover -2- on the wiring harness -3- toward the rear.
– Pull on the connector -1- without pressing the release to make
sure the connection is secure. If the connector was not con‐
nected correctly, it could cause a malfunction.
– Release and disconnect the connector -1-.
– Check the contacts on the connector and on the fuel delivery
unit for damage.
– Attach the -VAS5565- to the connector and to the fuel delivery
unit.
– Connect the -VAG1348/3A- to the -VAS5565- and the battery
positive terminal clamp in the engine compartment.
Note
This step allows the fuel pump to run when the engine is not run‐
ning.
– The fuel pump delivery rate is dependent on the battery volt‐
age. Also connect the Multimeter to the wires -1- and -5- in the
-VAS5565- .
– To do so, use the -VAG1594D- also.
– Remove the fuel lines -1- from the flange. Disconnect the con‐
nector couplings. Refer to
⇒ “4.1 Connector Couplings, Disconnecting”, page 62
.
WARNING
The fuel line is under pressure.
Fuel poses a risk of injury to the eyes and skin.
Wear protective eyewear and protective clothing to avoid injury
and contact with skin. Place a cleaning cloth around the con‐
nection point before loosening hose connections. Carefully
open the connection point to release the pressure.
– Connect the -VAS6550- to the fuel delivery unit -1- using the
-VAS6550/3-4- .
– Connect the -VAS6550/3-4- to the shut-off valve -A-.
– Connect the -VAS6550/4- to the connection -B- on the -
VAS6550- .
– Hold the open end of the -VAS6550/4- hose in a measuring
container.
– Make sure that the drain valve -C- on the Pressure Tester
-1- is closed.
– The shut-off valves -A and B- on the Pressure Tester Kit -1-
are opened.
– Push the -VAG1348/3A- .
Note
The Transfer Fuel Pump - G6- is activated!
– Adjust the pressure to 4.0 bar with the adjustment wheel on
the Pressure Regulating Valve -arrow-.
– From this point on do not move the adjustment wheel.
– Empty the measuring container.
– Press the remote control for 60 seconds while measuring the
fuel pump voltage.
– Compare the delivered quantity of fuel with the specified value
in the table.
Axis designation
Unit
Minimum delivery rate
cm
3
Fuel pump voltage when the
engine is idling and the pump is
running
Volt
Example:
During test, a voltage of 10.5 Volts is measured. This results in a
minimum delivery quantity of approximately 1200 cm
3
/60 s.
If the Specified Value is Obtained:
– Check the fuel lines for possible restrictions (kinks) or block‐
ages.
– Check the fuel lines for leaks and damage.
If the Specified Value is not Obtained:
– Remove the fuel delivery unit. Refer to
⇒ “2.2 Fuel Delivery Unit/Fuel Level Sensor, Removing and
– Check the filter screen for contaminants.
– Check whether the hose connections -arrows- to the fuel de‐
livery unit -1- are sealed.
– Check the fuel lines for possible restrictions (kinks) or block‐
ages.
– Check the fuel lines for leaks and damage.
If no Malfunction was Detected:
– Replace the fuel delivery unit. Refer to
⇒ “2.2 Fuel Delivery Unit/Fuel Level Sensor, Removing and
8.2
Fuel Pump Control Module - J538- , Re‐
moving and Installing
Special tools and workshop equipment required
♦ Trim Removal Wedge - 3409-
Procedure:
Removing
– Move the front seats all the way forward.
– Switch off the ignition.
Golf Sportsvan:
– Remove the right rear seat. Refer to ⇒ Body Interior; Rep. Gr.
72 ; Rear Seats; Bench Seat / Single Seat, Removing and In‐
stalling .
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