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Volkswagen Golf Service & Repair Manual: Emptying fuel tank less than 3/4 full, vehicles with four-wheel drive

Volkswagen Golf Service & Repair Manual / Fuel supply system - Petrol engines / Fuel supply, gas operation / Fuel tank / Emptying fuel tank less than 3/4 full, vehicles with four-wheel drive

Emptying fuel tank less than 3/4 full, vehicles with four-wheel drive

Special tools and workshop equipment required
Removal wedge -3409-
Special wrench -T10202-
Fuel extractor -VAS 5190A- (for E 85 fuel)
Fuel extractor -VAS 5190- (not shown)

 
–  Observe safety precautions → Chapter.
–  Observe rules for cleanliness → Chapter.
–  Move front seats to foremost position.
–  Remove bench seat → General body repairs, interior; Rep. gr.72.
–  Disconnect earth wire from battery terminal → Electrical system; Rep. gr.27.
Extract fuel from both chambers of fuel tank using fuel extractor -VAS 5190A- or fuel extractor -VAS 5190-.
   
–  Unclip cover -1- for left and right flange from retaining tabs -arrows- using removal wedge -3409-.
 

Emptying fuel tank less than 3/4 full, vehicles with four-wheel drive

–  Unclip right sealing grommet -1- downwards from cover -2-.
–  Push cover -2- back along wiring harness -3-.
 

Emptying fuel tank less than 3/4 full, vehicles with four-wheel drive

–  Push tab -2- upwards in -direction of arrow A-.
–  To do this, reach in with your finger between floor panel and fuel tank.
–  At the same time, carefully pull fuel pump control unit -J538--1- out of mounting -in direction of arrow B- by grasping hold of wiring harness -3-.
–  Guide fuel pump control unit -J538- out towards interior between fuel tank and floor panel.
–  Place fuel pump control unit -J538- together with wiring harness to one side.
 

Emptying fuel tank less than 3/4 full, vehicles with four-wheel drive

–  Disconnect connectors -1 and 2- as well as fuel line -3- from flange.
The fuel system is pressurised.Risk of injury due to fuel which may spurt out.Wear eye protection.Wear protective gloves.Release pressure: place clean cloth around connection and carefully open connection.
–  If fitted, remove fuel line -2- leading to metering pump -V54- for auxiliary heater from sealing flange.
–  To do this, loosen lower hose clip.
 

Emptying fuel tank less than 3/4 full, vehicles with four-wheel drive

–  Open locking ring using wrench -T10202-.
 

Emptying fuel tank less than 3/4 full, vehicles with four-wheel drive

–  Carefully lift flange of fuel delivery unit -3-.
–  Remove gasket -1- and carefully lift up the flange of the fuel delivery unit slightly more.
–  Secure earth wire of fuel extractor to a bare metal part of the body.
 

Emptying fuel tank less than 3/4 full, vehicles with four-wheel drive

–  Disconnect left connector -arrow-. Lay cover -1- with wiring harness to one side.
 

Emptying fuel tank less than 3/4 full, vehicles with four-wheel drive

–  Open locking ring using wrench -T10202-.
–  Insert extraction hose of fuel extractor -VAS 5190A- or fuel extractor -VAS 5190- as far as possible into fuel tank.
–  Using fuel extractor, extract fuel from both chambers.
If the fuel tank needs only to be emptied, reinstall fuel delivery unit → Chapter.
Specified torques
→ Chapter „Assembly overview - fuel delivery unit and fuel gauge sender“
 

Emptying fuel tank less than 3/4 full, vehicles with four-wheel drive

Emptying fuel tank with fuel tank more than 3/4 full, engine code CWVA
Special tools and workshop equipment required Removal wedge -3409- Wrench -T10202- Torque wrench -V.A.G 1332- Fuel extr ...

Fuel delivery unit, fuel gauge sender
...

Other materials:

Removing and installing lower part of sump
Special tools and workshop equipment required Flat scraper Commercially available scraper Sealant remover Hand drill with plastic brush attachment ...

Tyre pressure monitor
System description – Tyre Pressure Monitoring System General notes: The tyre pressure monitor display system is part of the software in the ABS control unit -J104-. The system is used to detect slow tyre pressure loss from a wheel. Event me ...

Safety precautions when working on high-voltage system
Danger to life due to high voltage The high-voltage system is under high voltage. There is a risk of severe or fatal injury due to electric shock. –  Persons with life-preserving or other electronic medical devices in or on their body must not perf ...

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