Fuel tank, emptying

Special tools, testers and auxiliary items required

Fig 1: Fuel Siphoning Unit VAS 5190

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fuel siphoning unit VAS 5190

Fig 2: Identifying Wrench T10202

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Vehicles from approx. 11/2002: Wrench T10202

Work procedure

Observe safety precautions → Safety precautions .

Observe rules for cleanliness → Rules for cleanliness .

Open fuel filler flap briefly and then close again.

CAUTION: Observe safety precautions when disconnecting the battery → 27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL .

Fig 3: Removing Cover Of Right Luggage Compartment Side Trim

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove cover of right luggage compartment side trim - arrows -.

Fig 4: Removing Cover Above Battery

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove cover - 1 - above battery.

NOTE:

Ignore - 2 -.

Fig 5: Disconnecting Battery Ground (GND) Strap

Courtesy of VOLKSWAGEN UNITED STATES, INC.

With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.

Fig 6: Removing/Installing Cover For Left Locking Flange

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove trim for luggage compartment floor.
Remove cover for left locking flange - arrows -.

Fig 7: Disconnecting/Connecting Electrical Connectors At Left Locking Flange

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical connectors - 1 - and - 2 - at left locking flange.

Fig 8: Removing/Installing Locking Ring Using Wrench T10202

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove locking ring using wrench T10202.

Fig 9: Removing/Installing Cover For Right Locking Flange

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove cover for right locking flange - arrows -.

Fig 10: Disconnecting/Connecting Electrical Connectors At Right Locking Flange

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical connectors - 1 - and - 2 - at right locking flange.

Fig 11: Identifying Fuel Return Line & Fuel Supply Line

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Mark fuel return line - 1 - and fuel supply line - 2 -.

CAUTION: Fuel system is under pressure! Before opening system, place clean rags around the connection. Then release pressure by carefully loosening the connection.

Pull both lines from locking flange, by pressing release buttons.

Fig 12: Removing/Installing Locking Ring Using Wrench T10202

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove locking ring using wrench T10202.

Fig 13: Connecting Ground (GND) Wire Of Fuel Extraction Unit VAS 5190 To Ground Terminal Of Energy Management Control Module J644

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Connect Ground (GND) wire of Fuel Extraction Unit VAS 5190 to ground terminal of energy management control module J644.
Pull off left locking flange and set aside with electrical wiring still connected.
Remove seal.
Extract fuel in left half of fuel tank through opening in fuel tank, using fuel extraction unit VAS 5190.

Fig 14: Pulling Off Right Locking Flange And Setting Aside With Electrical Wiring And Fuel Lines Still Connected

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull off right locking flange and set aside with electrical wiring and fuel lines still connected.
Remove seal.
Extract fuel in right half of fuel tank through opening in fuel tank, using fuel extraction unit VAS 5190.
Re-install locking flange: Left → Installing , Right → Installed location of right locking flange .