VW Golf manuals

Volkswagen Golf Service & Repair Manual: Emptying fuel tank when fuel pump is intact

Emptying fuel tank when fuel pump is intact

Special tools and workshop equipment required
Removal wedge -3409-
Remote control -V.A.G 1348/3A-
Test instrument adapter/DSO (5-pin) -VAS 5565-
Fuel extractor -VAS 5190-
Fuel extractor -VAS 5190 A- for E 85 fuel (not shown).
Adapter for fuel extraction -VAS 5190-

 
  Note
To extract E 85 fuel, use only fuel extractor -VAS 5190 A-!
 
   
Auxiliary measuring set -V.A.G 1594C-
  Note
 

Emptying fuel tank when fuel pump is intact

If the fuel extraction unit -VAS 5190- is still fitted with the extraction hose with a fixed tip, the extraction hose must be replaced with the version with a screw-in tip.
–  Observe safety instructions → Chapter.
–  Observe rules for cleanliness → Chapter.
 

Emptying fuel tank when fuel pump is intact

–  Pull off fuel supply line -1-. Separate plug-in connectors → Chapter.
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.
–  Collect escaping fuel with a cleaning cloth.
 

Emptying fuel tank when fuel pump is intact

–  Connect fuel extractor -VAS 5190- with adapter for fuel extractor -VAS 5190 /3- to fuel supply line.
–  Secure earth wire of fuel extractor to a bare metal part of the body.
Golf SV:
–  Remove right rear seat → General body repairs, interior; Rep. gr.72.
 

Emptying fuel tank when fuel pump is intact

–  Partially detach cover -1- in floor covering at parting line -arrow-.
–  Do not detach cover completely from floor covering in order to ensure it is reinstalled in the correct installation position.
–  Detach it just enough that the cover can be folded upwards.
–  Fold up cover in -direction of arrow-.
Golf and Golf Estate:
–  Remove rear bench seat → General body repairs, interior; Rep. gr.72.
 

Emptying fuel tank when fuel pump is intact

Continuation for all vehicles:
–  Unclip cover -1- for flange at retaining tabs -arrows-, using removal wedge -3409-.
 

Emptying fuel tank when fuel pump is intact

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

Emptying fuel tank when fuel pump is intact

–  Release and pull off connector -1- on sealing flange.
 

Emptying fuel tank when fuel pump is intact

–  Connect test instrument adapter/DSO (5-pin) -VAS 5565- to fuel delivery unit -1-.
–  Connect remote control -V.A.G 1348/3A- to adapter -VAS 5565- and to battery positive terminal in engine compartment.
–  Connect connection -5- (yellow) of test instrument adapter/DSO (5-pin) -VAS 5565- to battery negative terminal using suitable workshop equipment -3-.
–  Also use auxiliary measuring set -V.A.G 1594C- for this purpose.
  Note
This step serves only to have the fuel pump running when the engine is stopped.
 

Emptying fuel tank when fuel pump is intact

–  Open tank flap unit -2-.
–  Clean area around fuel filler neck.
–  Unscrew cap -1- for fuel filler neck.
–  Operate remote control -V.A.G 1348/3A- and shut-off tap on fuel extractor -VAS 5190- until fuel tank is empty.
  Note
Risk of damage to fuel system pressurisation pump -G6- when the fuel tank is empty. The fuel system pressurisation pump -G6- must not run »dry«.
 

Emptying fuel tank when fuel pump is intact

Removing and installing fuel tank, vehicles with multi-link rear suspension and fuel tank leakage diagnosis function
Special tools and workshop equipment required     Torque wrench -V.A.G 1331-   ...

Emptying fuel tank with fuel pump intact, engine code CWVA
Special tools and workshop equipment required Removal wedge -3409- Remote control -V.A.G 1348/3A- Test instrument adapter/DSO (5-pin) -V ...

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