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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:

Dimensions - lettering on rear lid, “GTI/GTD”
  Note When fitting the lettering, observe the fitting notes → Anchor. 1 -  Lettering Model designation 2 -  Height dimension 75.5 ± 1 mm, from lower edge of lettering to tail light. ...

Adjusting bonnet
Adjusting bonnet Special tools and workshop equipment required         Torque wrench -V.A.G 1331- Note Vehicle must be standing on its wheels to enable bonnet to ...

Assembly overview - data bus diagnostic interface
1 -  Electrical connector For data bus diagnostic interface -J533- 2 -  Data bus diagnostic interface -J533- Removing and installing → Chapter 3 -  Bolt Spe ...

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