Volkswagen Golf 2015 Repair Manual
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Volkswagen Golf 2015 Repair Manual

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Service
Repair Manual
Golf 2015 ➤
Golf Variant 2015 ➤
Fuel Supply - Gasoline Engines
Engine ID
Edition 01.2016
Service Department. Technical Information
CNT
CXB
CNS
A
A
A
CXB
CNS
CXC
B
B
A
CXC
B

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Summary of Contents for Volkswagen Golf 2015

  • Page 1 Service Repair Manual Golf 2015 ➤ Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines Engine ID Edition 01.2016 Service Department. Technical Information...
  • Page 2 In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed. All rights reserved. No reproduction without prior agreement from publisher. Copyright © 2016 Volkswagen AG, Wolfsburg D4B80416623...

  • Page 3: Table Of Contents

    Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 Contents 00 - General, Technical Data ..........
  • Page 4 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 Contents...

  • Page 5: General, Technical Data

    Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 00 – General, Technical Data Safety Precautions (Edition 01.2016) ⇒ 1.1 Safety Precautions when Working on Fuel Supply System , page 1 ⇒ 1.2 Safety Precautions during Road Test with Testing Equip‐...

  • Page 6: Safety Precautions When Working On Vehicles With Start/Stop System

    Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Have a second technician operate the testing equipment on the rear seat. Safety Precautions when Working on Vehicles with Start/Stop System WARNING There is a risk of injury due to the engine starting unexpectedly.

  • Page 7: Identification

    Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 Identification ⇒ 2.1 Engine Number/Engine Characteristics , page 3 Engine Number/Engine Characteristics Codes CXBA CXBB CNSA CNSB Emissions values SULEV SULEV SULEV SULEV Displace‐...

  • Page 8: General Information

    Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 General Information ⇒ 3.1 Parking/Auxiliary Heater and Fuel System Clean Working Conditions , page 4 Parking/Auxiliary Heater and Fuel Sys‐ tem Clean Working Conditions Special tools and workshop equipment required ♦...

  • Page 9: Repair Information

    Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 Repair Information ⇒ 4.1 Wire Routing and Securing , page 5 ⇒ 4.2 General Repair Information , page 5 Wire Routing and Securing WARNING There is a risk of damaging lines.

  • Page 10: Fuel Supply

    Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 20 – Fuel Supply Fuel Tank ⇒ 1.1 Overview - Fuel Tank , page 6 ⇒ 1.2 Fuel Tank, Removing and Installing , page 11 ⇒...
  • Page 11 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 3 - Bleeder Line ❑ To the EVAP Canister Purge Regulator Valve 1 - N80- ❑ Clipped to the fuel tank ❑ Do not kink ❑...
  • Page 12 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 13 - Bolt ❑ 20 Nm + 90° ❑ Replace after removing. 14 - Nut ❑ 2 Nm ❑ For the heat shield 15 - Heat Shield ❑...
  • Page 13 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 7 - Fuel Tank ❑ Removing and Installing. Refer to ⇒ 1.2.3 Fuel Tank, Removing and Installing, Vehicles with Torsion Beam Rear Suspension ,...
  • Page 14 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 1.1.3 Overview - Fuel Tank, Vehicles with Fuel Tank Leak Detection 1 - Cap ❑ Turn until it clicks into place. ❑ Attached to the fuel filler...

  • Page 15: Fuel Tank, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 11 - Metal Nut ❑ For the heat shield 12 - Bolt ❑ 20 Nm +90° ❑ Replace after removing. 13 - Mounting Strap ❑...
  • Page 16 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 Golf Sportsvan: – Remove the right rear seat. Refer to ⇒ Body Interior; Rep. Gr. 72 ; Rear Seats; Bench Seat / Single Seat, Removing and In‐...
  • Page 17 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Lift the tab -2- in the direction of the -arrow A- by using a finger to reach between the floor panel and the fuel tank.
  • Page 18 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Disconnect the vent lines -1 and 2- from the EVAP canister. Disconnect the connector couplings. Refer to ⇒ 4.1 Connector Couplings, Disconnecting , page 62 –...
  • Page 19 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Press the lever -2- on the brake caliper in the direction of the -arrow- and disengage the brake cable -1-. – Press the tabs -3- together and remove the brake cable from the bracket -4- on the brake caliper.
  • Page 20 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Remove the bolts -1 and 3-. Note To improve clarity, the fuel tank is shown without the - ♦ VAS6931- . A second technician is required to remove the fuel tank.
  • Page 21 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Check the ground cable for traces of oxidation on the connec‐ tors. Remove any oxidation if necessary. – Check the installation position of the ground connection.
  • Page 22 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Move the front seats all the way forward. – Switch off the ignition. – Remove the rear bench seat. Refer to ⇒ Body Interior; Rep.
  • Page 23 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Open the fuel filler door unit -2-. – Clean the area around the fuel filler neck. – Remove the cap -1- for the fuel filler neck.
  • Page 24 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Release the connector -arrow- and remove. – Unclip the wiring harness -1- from the brackets -arrows-. – Remove the exhaust system rear section. Refer to ⇒ Rep. Gr.
  • Page 25 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Unclip the parking brake cable -4- from the bracket -arrow A-. – Pull the parking brake cable out of the guide -arrow B- on the bracket -3-.
  • Page 26 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Remove the bolts -1 and 3-. Note To improve clarity, the fuel tank is shown without the - ♦ VAS6931- . A second technician is required to remove the fuel tank.
  • Page 27 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Check the ground cable for traces of oxidation on the connec‐ tors. Remove any oxidation if necessary. – Check the installation position of the ground connection.
  • Page 28 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Drain the fuel tank. Refer to ⇒ 1.3 Fuel Tank, Draining , page 35 – Move the front seats all the way forward.
  • Page 29 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Unlock and disconnect the connectors -1- from the sealing flange. – If equipped, release the connector -2- for the Metering Pump - V54- and remove it.
  • Page 30 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Disconnect the vent lines -1 and 2- from the EVAP canister. Disconnect the connector couplings. Refer to ⇒ 4.1 Connector Couplings, Disconnecting , page 62 –...
  • Page 31 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 Vehicles with Parking Heater: – Remove the fuel line -1- from the parking heater. Disconnect the connector couplings. Refer to ⇒ 4.1 Connector Couplings, Disconnecting , page 62 –...
  • Page 32 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Remove the bolts -2, 4 and 6-. Note To improve clarity, the fuel tank is shown without the - ♦ VAS6931- . A second technician is required to remove the fuel tank.
  • Page 33 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Check the ground cable for traces of oxidation on the connec‐ tors. Remove any oxidation if necessary. – Check the installation position of the ground connection.
  • Page 34 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Drain the fuel tank. Refer to ⇒ 1.3 Fuel Tank, Draining , page 35 – Move the front seats all the way forward.
  • Page 35 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Release and disconnect the connector -arrow-. – Open the fuel filler door unit -2-. – Clean the area around the fuel filler neck.
  • Page 36 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Unclip the breather lines -1- at the bracket -arrow-. – Remove the rear axle. Refer to ⇒ Suspension, Wheels, Steer‐ ing; Rep. Gr. 42 ; Rear Axle; Rear Axle, Removing and Installing .
  • Page 37 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 Continuation for All Vehicles: – Remove the bolt -5-. – Remove the bracket for the exhaust system -arrow-. – Remove the bolt -3- and remove the mounting strap -7-.
  • Page 38 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Remove the bolts -2, 4 and 6-. Note To improve clarity, the fuel tank is shown without the - ♦ VAS6931- . A second technician is required to remove the fuel tank.

  • Page 39: Fuel Tank, Draining

    Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Check the ground cable for traces of oxidation on the connec‐ tors. Remove any oxidation if necessary. – Check the installation position of the ground connection.
  • Page 40 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 ♦ Connector Test Set - VAG1594D- ♦ Injection Rate Comparison Meter Kit - Remote Cable - VAG1348/3A- ♦ Vehicle Diagnostic Tester - Test Adapter - 5 Pin - VAS5565- ♦...
  • Page 41 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Connect the -VAS 5190- and -VAS5190 /3- to the fuel supply line. – Attach the ground wire of the -VAS5190A- to a bare area on the body.
  • Page 42 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Unlock and disconnect the connector -1- from the sealing flange. – Connect the -VAS5565- to the fuel delivery unit -1-. – Connect the -VAG1348/3A- to the -VAS5565- and the battery positive terminal clamp in the engine compartment.
  • Page 43 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 ♦ Trim Removal Wedge - 3409- ♦ Connector Test Set - VAG1594D- ♦ Injection Rate Comparison Meter Kit - Remote Cable - VAG1348/3A- ♦ Vehicle Diagnostic Tester - Test Adapter - 5 Pin - VAS5565-...
  • Page 44 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 ♦ Fuel Extractor VAS5190A - VAS5190- ♦ Fuel Extraction Unit - VAS5190 A- (not illustrated) for E 85 - fuel. ♦ Fuel Extraction Adapter - VAS5190-...
  • Page 45 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Disconnect the fuel supply line -1-. Disconnect the connector couplings. Refer to ⇒ 4.1 Connector Couplings, Disconnecting , page 62 WARNING The fuel line is under pressure.
  • Page 46 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 Continuation for All Vehicles: – Unclip the sealing flange cover -1- at the tabs -arrows- using the Trim Removal Wedge - 3409- . – Unclip the grommet -1- downward out of the cover -2-.
  • Page 47 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Open the fuel filler door unit -2-. – Clean the area around the fuel filler neck. – Remove the cap -1- for the fuel filler neck.
  • Page 48 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Open the fuel filler door unit -2-. – Clean the area around the fuel filler neck. – Remove the cap -1- for the fuel filler neck.
  • Page 49 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 Note Use only the -VAS5190A- when extracting E 85 - fuel! – Pay attention to all safety precautions. Refer to ⇒ 1 Safety Precautions , page 1 –...
  • Page 50 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Unlock and disconnect the connector -1- from the sealing flange. – If equipped, disengage the connector -2- for the parking heater Metering Pump - V54- on the sealing flange and move it to the side.
  • Page 51 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Carefully lift the fuel delivery unit flange -3-. – Remove the seal -1- and slightly lift the fuel delivery unit flange again carefully.
  • Page 52 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 ♦ Wrench - Fuel Sending Unit - T10202- ♦ Torque Wrench 1332 40-200Nm - VAG1332- Note Use only the Fuel Extractor Unit - VAS5190 A- when extracting E 85 - fuel! –...
  • Page 53 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 Continuation for All Vehicles: – Unclip the sealing flange cover -1- at the tabs -arrows- using the Trim Removal Wedge - 3409- . – Unclip the grommet -1- downward out of the cover -2-.
  • Page 54 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Open the locking ring using the Wrench - Fuel Sending Unit - T10202- . – Carefully lift the fuel delivery unit flange -3-.

  • Page 55: Fuel Delivery Unit/Fuel Level Sensor

    Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 Fuel Delivery Unit/Fuel Level Sensor ⇒ 2.1 Overview - Fuel Delivery Unit/Fuel Level Sensor , page 51 ⇒ 2.2 Fuel Delivery Unit/Fuel Level Sensor, Removing and In‐...

  • Page 56: Fuel Delivery Unit/Fuel Level Sensor, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 ❑ Make sure it is attached securely and pull on it to make sure the connector it is properly locked. 7 - Fuel Supply Line ❑...
  • Page 57 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Drain the fuel tank. Refer to ⇒ 1 Fuel Tank , page 6 Golf Sportsvan: – Remove the right rear seat. Refer to ⇒ Body Interior; Rep. Gr.
  • Page 58 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Remove the fuel line -1- from the sealing flange. Disconnect the connector couplings. Refer to ⇒ 4.1 Connector Couplings, Disconnecting , page 62 WARNING The fuel line is under pressure.
  • Page 59 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Pull the fuel delivery unit -2- as far as possible out of the fuel tank. – Release the fuel line -1- in the fuel tank and disconnect it from the suction line -3-.

  • Page 60: Fuel Level Sensor G , Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Tighten the locking ring using the -T10202- . – Attach the fuel line -1- to the sealing flange until it clicks into place.
  • Page 61 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Unlock and disconnect the connectors -1- from the sealing flange. – Disengage and free up the wires on the bracket -arrow-. – Unlock the retainers -3- and -4-.

  • Page 62: Wiring

    Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 Wiring ⇒ 3.1 Fuel Lines, Removing and Installing , page 58 Fuel Lines, Removing and Installing Removing – If equipped, remove the underbody trim panel in front of the right rear axle.
  • Page 63 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – If equipped remove the heat shield -1- from the ABS Hydraulic Unit - N55- . – To do so, unclip the heat shield -1- from the bracket -2- -arrow-.
  • Page 64 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 Continuation for All Vehicles: – Unclip the shield -1- on the stud bolt from the body -arrow A-. – Unclip the shield -1- from the longitudinal member -2-.
  • Page 65 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 Installation Position of the Fuel Lines on the Coupling Point in Engine Compartment: Fuel Supply Line Bleeder Line Installation Position of the Fuel Lines on the Underbody:...

  • Page 66: Connector Couplings

    Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 Connector Couplings ⇒ 4.1 Connector Couplings, Disconnecting , page 62 Connector Couplings, Disconnecting Special tools and workshop equipment required ♦ Lever - Fuel Line - T10468-...
  • Page 67 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 Opening It is necessary to counterhold the fuel separating point -1- inside the engine compartment. – Insert the -T10468- between the heat shield and the stop -arrow- for the fuel line -2- and counterhold it.
  • Page 68 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 Opening – Push the connector coupling -1- in the direction of the -arrow A-. – Pull the pull release -2- in the direction of the -arrow B-.
  • Page 69 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 Version 6 Connector coupling with right and left release buttons -arrows-: Opening – Press the connector coupling -1- in the direction of the -arrow- and hold it down.

  • Page 70: Fuel Filter

    Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 Fuel Filter The pressure relief valve and the fuel filter are integrated in the fuel delivery unit and cannot be replaced separately. Refer to ⇒...

  • Page 71: Evap System

    Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 EVAP System ⇒ 6.1 Connection Diagram - EVAP System , page 67 ⇒ 6.2 Overview - EVAP System , page 69 ⇒ 6.3 EVAP Canister, Removing and Installing , page 70 ⇒...
  • Page 72 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 1 - EVAP Canister ❑ Component location: under the wheel hous‐ ing liner in the right rear wheel housing ❑ Removing and Instal‐ ling. Refer to ⇒...

  • Page 73: Overview - Evap System

    Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 Overview - EVAP System ⇒ 6.2.1 Overview - EVAP System, with Fuel Tank Leak Detec‐ tion , page 69 ⇒ 6.2.2 Overview - EVAP System, without Fuel Tank Leak De‐...

  • Page 74: Evap Canister, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 ❑ Connection Diagram. Refer to ⇒ Fig. Connection Diagram on EVAP Canister , page 68 6.2.2 Overview - EVAP System, without Fuel Tank Leak Detection 1 - Connecting Hose ❑...
  • Page 75 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Follow the guidelines for clean working conditions. Refer to ⇒ 3.1 Parking/Auxiliary Heater and Fuel System Clean Work‐ ing Conditions , page 4 –...

  • Page 76: Fuel Tank, Checking Ventilation

    Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Remove the right rear wheel housing liner. Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Wheel Housing Liner; Overview - Rear Wheel Housing Liner .
  • Page 77 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Release and remove the breather line -2-. Disconnect the connector couplings. Refer to ⇒ 4.1 Connector Couplings, Disconnecting , page 62 – Connect the -VAS6213- to line leading to the EVAP Canister Purge Regulator Valve 1 - N80- using the -VAS6550/3-1- and a commercially available hose.
  • Page 78 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Connect the - VAS6213- with the -VAS6550/3-2- to the EVAP canister line. – Set the slide ring -1- on the -VAS6213- in position -A- for vac‐...
  • Page 79 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Seal the connection -3- using suitable service equipment. – Seal the connection -A- on the EVAP canister -2- with a suit‐ able plug from the -VAS6122- -1-.

  • Page 80: Fuel System, Checking For Leaks

    Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 If a Vacuum Forms: – Check the line between the separating point -2- in the engine compartment and the connection -M- on the EVAP canister, replacing if necessary.
  • Page 81 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Set the valve -D- to Hold . – Open the nitrogen bottle -H-. – Connect the measuring hose -G- to the self-test connection -B-.
  • Page 82 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Set the valve -D- to Test . The fuel system is now filled. – Watch the pressure gauge -C- and the flow meter -E-. The fuel system is filled if the flow rate decreases and the pressure in‐...

  • Page 83: Accelerator Mechanism

    Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 Accelerator Mechanism ⇒ 7.1 Overview - Accelerator Pedal Module , page 79 ⇒ 7.2 Accelerator Pedal Position Sensors G79 / G185 , Remov‐ ing and Installing , page 80...

  • Page 84: Accelerator Pedal Position Sensors G79 / G185 , Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 Accelerator Pedal Position Sensors - G79- / -G185- , Removing and Installing Removing – Fold the carpet -1- forward in the direction of the -arrow-.

  • Page 85: Fuel Pump

    Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 Fuel Pump ⇒ 8.1 Transfer Fuel Pump G6 , Checking , page 81 ⇒ 8.2 Fuel Pump Control Module J538 , Removing and Instal‐...
  • Page 86 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Connect the Vehicle Diagnostic Tester -1- as follows: – Connect the diagnostic cable connector -2- to the diagnostic connection inside the driver footwell.
  • Page 87 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Unclip the grommet -1- downward out of the cover -2-. – Guide the cover -2- on the wiring harness -3- toward the rear.
  • Page 88 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 If no faults can be found: WARNING The fuel line is under pressure. Fuel poses a risk of injury to the eyes and skin.
  • Page 89 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 Test Sequence: Note The output diagnostic test mode checks the fuel pump function. – Pay attention to all safety precautions. Refer to ⇒ 1 Safety Precautions , page 1 –...
  • Page 90 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 Continuation for All Vehicles: – Unclip the right sealing flange cover -1- at the tabs -arrows- using the -3409- . – Unclip the grommet -1- downward out of the cover -2-.
  • Page 91 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 If no faults can be found: WARNING The fuel line is under pressure. Fuel poses a risk of injury to the eyes and skin.
  • Page 92 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Remove the supply line -1-. Disconnect the connector cou‐ plings. Refer to ⇒ 4.1 Connector Couplings, Disconnecting , page 62 WARNING The fuel line is under pressure.
  • Page 93 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – 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 - VAS6550- -1- are opened.
  • Page 94 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 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-.
  • Page 95 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Connect the -VAS6550- to the fuel delivery unit -1- using the -VAS6550/3-4- . – Connect the -VAS6550/3-3- between the -VAS6550- and the fuel supply line -2-.
  • Page 96 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 Conditions: • Power supply is OK. ⇒ 8.1.1 Fuel Pumps, Checking Function and Power Supply , page 81 – Pay attention to all safety precautions. Refer to ⇒...
  • Page 97 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Make sure that the drain valve -C- on the Pressure Tester -1- is closed. – The shut-off valves -A- and -B- on the -VAS6550- -1- are opened.
  • Page 98 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 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-.
  • Page 99 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Make sure that the drain valve -C- on the Pressure Tester -1- is closed. – The shut-off valves -A and B- and -B- on the -VAS6550- -1- are opened.
  • Page 100 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Connect the -VAS6550/2- between the fuel line from the fuel tank and the shut-off valve -B- on the -VAS6550- . – Connect the -VAS6550/1- between the fuel line leading to the engine -1- and the shut-off valve -A- on the -VAS6550- .
  • Page 101 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 If no faults can be found: – 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.
  • Page 102 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 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-.
  • Page 103 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Connect the -VAS6550- to the fuel delivery unit -1- using the -VAS6550/3-4- . – Connect the -VAS6550/3-3- between the -VAS6550- and the fuel line -2-.
  • Page 104 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 ♦ Trim Removal Wedge - 3409- ♦ Pressure Tester Kit - VAS6550- ♦ Pressure Tester Kit - Adapter Set - Hose 3 - VAS6550/3-3- ♦...
  • Page 105 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Connect the Pressure Tester Kit - Hose 2 - VAS6550/2- be‐ tween the fuel line from the fuel tank and the shut-off valve -B- on the Pressure Tester Kit - VAS6550- .
  • Page 106 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 If no faults can be found: – 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.
  • Page 107 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 Continuation for All Vehicles: – Unclip the sealing flange cover -1- at the tabs -arrows- using the Trim Removal Wedge - 3409- . – Unclip the grommet -1- downward out of the cover -2-.
  • Page 108 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – 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.
  • Page 109 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 Perform the following work: Checking the Fuel Delivery Rate Inside the Engine Compartment, Quick Test: Note The fuel delivery rate is first checked in the engine compartment with the Check fuel delivery rate, quick test Guided Function.
  • Page 110 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 If the Specified Value is not Obtained: – Open the fuel filler door unit -2-. – Clean the area around the fuel filler neck.
  • Page 111 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – 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.
  • Page 112 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – 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.
  • Page 113 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – 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- .
  • Page 114 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Compare the delivered quantity of fuel with the specified value in the table. Axis designation Unit Minimum delivery rate Fuel pump voltage when the...
  • Page 115 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 Perform the following work: Fuel Delivery Rate, Checking in Engine Compartment, Quick Test: Note The fuel delivery rate is first checked in the engine compartment with the Check fuel delivery rate, quick test Guided Function.
  • Page 116 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 If the Specified Value is not Obtained: – Open the fuel filler door unit -2-. – Clean the area around the fuel filler neck.
  • Page 117 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – 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.
  • Page 118 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – 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.
  • Page 119 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – 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- .

  • Page 120: Fuel Pump Control Module J538 , Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Compare the delivered quantity of fuel with the specified value in the table. Axis designation Unit Minimum delivery rate Fuel pump voltage when the...
  • Page 121 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – 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.
  • Page 122 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Lift the tab -2- -arrow A- so that it is possible to reach between the floor panel and the fuel tank. – At the same time, pull the Fuel Pump Control Module -1- care‐...

  • Page 123: Sensors

    Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 Sensors ⇒ 9.1 Fuel Tank Pressure Sensor G400 , Removing and Instal‐ ling , page 119 ⇒ 9.2 Fuel Tank Leak Detection Control Module J909 , Remov‐...

  • Page 124: Fuel Tank Leak Detection Control Module J909 , Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Remove the pressure regulating valve -1- from the seal -3- on the EVAP canister -2- in the -direction of the arrow-. Installing Install in reverse order of removal. Note the following: –...
  • Page 125 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 – Engage the Fuel Tank Leak Detection Control Module - J909- -1- correctly in the mount -2-. – Pull the Fuel Tank Leak Detection Control Module - J909- evenly downward until it engages audibly.

  • Page 126: Special Tools

    Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 Special Tools Special tools and workshop equipment required ♦ Trim Removal Wedge - 3409- ♦ Wrench - Fuel Sending Unit - T10202- ♦ Torque Wrench 1332 40-200Nm - VAG1332- ♦...
  • Page 127 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 ♦ Pressure Tester Kit - VAS6550- ♦ Pressure Tester Kit - Adapter Set - Hose 3 - VAS6550/3-3- ♦ Pressure Tester Kit - Adapter Set - Hose 4 - VAS6550/3-4- ♦...
  • Page 128 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 ♦ Torque Wrench 1331 5-50Nm - VAG1331- ♦ Connector Test Set - VAG1594D- ♦ Engine Bung Set - VAS6122- ♦ Hand Vacuum Pump - VAS6213-...
  • Page 129 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 ♦ Pressure Tester Kit - Adapter Set - Hose 3 - VAS6550/3-3- ♦ Pressure Regulator Valve - VAS6550/4- ♦ Engine and Gearbox Jack - VAS6931- ♦...
  • Page 130 Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 ♦ Fuel Extractor Unit - VAS5190A- (without illustration) for E 85 - fuel type. ♦ Vehicle Diagnostic Tester - Test Adapter - 5 Pin - VAS5565- ♦...

  • Page 131: Revision History

    Golf 2015 ➤ , Golf Variant 2015 ➤ Fuel Supply - Gasoline Engines - Edition 01.2016 Revision History DRUCK NUMBER: K0059240921 Fac‐ Edit Notes Quality tory Edi‐ Type Checke Edi‐ tion d By tion 01.2 02/2 Fac‐ Joe Y 4/20 tory Up‐...
  • Page 132 All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
  • Page 133 All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
  • Page 134 All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

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