Fuel tank, draining

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Special tools, testers and auxiliary items required

Fig 1: Identifying Wrench T10202

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Wrench T10202

Fig 2: Identifying Fuel Extraction Unit VAS 5190

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fuel siphoning unit VAS 5190

Work procedure

Observe safety precautions → Safety precautions when working on fuel supply system .

Observe rules for cleanliness → Rules for cleanliness .

CAUTION:

Observe procedures for disconnecting battery →
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET
.

Fig 3: Pushing Cover Over Battery Toward Right And Removing It Upward

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Push cover over battery toward right - arrow 1 - and remove it upward - arrow 2 -.

Fig 4: Locating Battery Ground Strap

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

CAUTION: Secure Ground (GND) wire of fuel extraction unit VAS 5190 to a bare area of the chassis.

Fig 5: Pulling Cone Piece From Shaft Piece Of Fuel Siphoning Device VAS 5190

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull cone piece - 2 - from shaft end - 1 - of fuel extraction unit VAS 5190.
Using insulating tape, apply a mark - arrow - on hose at length - a - = 1,865 mm from end of suction hose.
Remove fuel filler cap from fuel filler tube.

Fig 6: Installing Fuel Siphoning Device VAS 5190 Onto Fuel Filler Tube Of Fuel Tank

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Screw shaft end - 1 - of fuel extraction unit VAS 5190 on to fuel filler tube of fuel tank.
Push suction hose as far into fuel tank until mark applied earlier - arrow - is positioned on shaft end.

Fig 7: Sliding Suction Hose As Far Into Fuel Tank Until Mark Applied Earlier Meets Fuel Filler Tube

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

If using a siphoning device without shaft end, proceed basically in the same manner.
In this case, apply a mark - arrow - using insulating tape on hose at length - a - = 1,800 mm from end of suction hose. The suction hose is inserted correctly when the marking applied earlier stands opposite the lip of fuel filler tube.
If the hose can only be inserted with difficulty, coat it thinly with engine oil. Never use lubricants containing silicon.

Drain fuel tank through fuel filler tube as much as possible.
Carefully pull out suction hose.
Remove rear seat bench →
- 72 - SEAT - FRAMES
- 72 - SEAT - FRAMES for BODY INTERIOR - CABRIOLET
.

Fig 8: Removing Cover Bolts For Locking Flange

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unbolt cover for right locking flange - arrows -.

Fig 9: Identifying Right Locking Flange Electrical Harness Connectors

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Disconnect electrical harness connector - 1 - at right locking flange.
Disengage electrical harness connector - 2 - and lay it aside.

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

Fig 10: Identifying Fuel Line & Ventilation Line

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect fuel line - 1 - from locking flange by pressing release button.
Disconnect ventilation line - 2 - by pressing release buttons.

Fig 11: Removing/Installing Locking Ring With Wrench T10202

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove locking ring with wrench T10202.
Pull locking flange and sealing ring from opening of fuel tank.

Fig 12: Separating Electrical Connection On Inner Side Of Locking Flange

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical connection on the inner side of the locking flange - arrow -.

Fig 13: Inserting Suction Hose Through Right Opening Of Fuel Tank Into Left Fuel Tank Chamber

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert suction hose, a dimension of - x - = 800 mm in length, through right opening of fuel tank into left fuel tank chamber.
Drain left fuel tank chamber.
Install right locking flange again Installing , observing notes for connecting battery →
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET
.