Fuel Tank, Draining When Less Than 3/4 Full

WARNING: This page is about a different car, the 2015 Volkswagen Beetle, 2014 Volkswagen Beetle, and 2013 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Fuel Extracting DeviceVAS5190
Wrench - Fuel Sending UnitT10202
Torque Wrench 1332 40-200NmVAG 1332
Trim Removal Wedge3409

WARNING:

To prevent large quantities of fuel from leaking from the fuel delivery unit when removing, the fuel tank may only be a maximum of ¹ /₃ full.

-- Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

-- Follow the guidelines for clean working conditions. Refer to PARKING/AUXILIARY HEATER AND FUEL SYSTEM CLEAN WORKING CONDITIONS .

-- Remove the rear bench seat. Refer to REAR SEATS .

-- Unclip the locking flange cover -1- at the tabs -arrows- using the Trim Removal Wedge3409.

Fig 1: Identifying Right Cover

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the connector -arrow-.

Fig 2: Fuel Pump Control Module Connector

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Release the fuel lines -1- and -2- from the flange and disconnect them. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, SEPARATING .

Fig 3: Fuel Lines At Flange

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

WARNING:

Fuel lines are under pressure.

Danger of personal injury to eyes and skin.

Wear protective eyewear and protective clothing in order to avoid injury and contact with the skin. Wrap a cloth around the connection before loosening hose connections. Open the connection carefully and release the pressure.

-- Open the locking ring with Wrench - Fuel Sending UnitT10202.

Fig 4: Identifying Locking Ring And Wrench T10202

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

CAUTION:

Do not bend the Wrench - Fuel Sending UnitT10202 and push hard on the locking ring. If the wrench slides down, the fuel delivery unit can be damaged.

-- Carefully lift the fuel delivery unit flange.

-- Insert the suction hose for the Fuel Siphoning DeviceVAS5190 as deep as possible into the fuel tank.

-- Extract the fuel.

Install the fuel delivery unit again if the fuel tank is only being emptied. Refer to FUEL DELIVERY UNIT/FUEL LEVEL SENSOR, REMOVING AND INSTALLING .

Tightening Specifications