With The Fuel Delivery Unit Installed

WARNING: This page is about a different car, the 2009 Volkswagen Rabbit, 2008 Volkswagen Rabbit, 2007 Volkswagen Rabbit, and 2006 Volkswagen Rabbit. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Adapter Set for Fuel Extraction VAS 5190/10
Test Instrument Adapter/DSO (5-pin) VAS 5565
Remote Control V.A.G 1348/3A

NOTE:

If the fuel extracting device VAS 5190 has a suction hose with a mounted tip -1-, then replace this with one that has a tip -2- which screws on.

Fig 1: Fuel Extracting Device

GWWA20-10555

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

WARNING:

The fuel supply line is under pressure. Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Wrap a cloth around the connection before disconnecting a fuel hose. Remove the hose connection carefully to release the pressure.
Connect the fuel extracting device VAS 5190 ground strap to the vehicles ground strap.

-- Disconnect the fuel supply line (metal coupling) -1- and catch any leaking fuel with a clean cloth. Disconnecting the couplings, refer to COUPLING, DISCONNECTING .

Fig 2: Disconnecting Fuel Supply Line

GWWN10-10528

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Connect the fuel extracting device VAS 5190 and the adapter for fuel extraction VAS 5190/3 to the fuel supply line.

Fig 3: Connecting Fuel Extracting Device VAS 5190 And Fuel Extracting Adapter VAS 5190/3 To Fuel Supply Line

GWWN20-10482

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the rear seat bench. Refer to "Rear Seats" in Removal and Installation .

-- Fold up the carpet to the right of the fuel delivery unit.

-- Remove the cover -1-.

Fig 4: Identifying Cover With Fuel Pump Control Module J538

GWWN20-0603

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the connector -arrow-.

Fig 5: Identifying Fuel Pump Control Module Connector

GWWN20-10623

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Connect the test instrument adapter/DSO (5-pin) VAS 5565 between the connectors on the fuel delivery unit and cover.

Fig 6: Connecting Remote Control V.A.G 1348/3A To Test Instrument Adapter/DSO (5-Pin) VAS 5565 And To Battery Plus (+)

GWWN20-10422

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Connect the remote control V.A.G 1348/3A to the test instrument adapter/DSO (5-pin) VAS 5565 and to the battery positive (+) terminal.

NOTE:

This step allows the fuel pump to run when the engine is not running.

-- Remove the cap from the fuel filler tube.

-- Operate the remote control V.A.G 1348/3A and the shut off lever on the fuel extracting device VAS 5190 until the fuel tank is empty.

CAUTION:

Do not run the fuel pump when it is dry.