Volkswagen Golf Service & Repair Manual: Emptying fuel tank less than 3/4
full, vehicles with four-wheel drive
| Special tools and workshop equipment required |
| 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-. |
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| – |
Unclip cover -1- for left and
right flange from retaining tabs -arrows-
using removal wedge -3409-. |
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| – |
Unclip right sealing grommet -1-
downwards from cover -2-. |
| – |
Push cover -2- back along
wiring harness -3-. |
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| – |
Push tab -2- upwards in
-direction of arrow A-. |
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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. |
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| – |
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. |
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| – |
Open locking ring using wrench -T10202-. |
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| – |
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. |
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| – |
Disconnect left connector -arrow-.
Lay cover -1- with wiring harness
to one side. |
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| – |
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. |
| → Chapter „Assembly overview - fuel delivery unit and fuel gauge
sender“ |
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 |
Special tools and workshop equipment required
Removal wedge -3409-
Wrench -T10202-
Torque wrench -V.A.G 1332-
Fuel extr ...
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Emptying fuel tank with fuel tank more than 3/4
full, engine code CWVA