Fuel Tank, Draining When Less Than 3/4 Full

WARNING: This page is about a different car, the 2016 Volkswagen Beetle, 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

Trim Removal Wedge 3409
Wrench - Fuel Sending Unit T10202
Torque Wrench 1332 40-200 Nm VAG 1332
Fuel Extraction Unit VAS 5190
Fuel Extractor Unit VAS 5190A (without illustration) for E 85 - fuel type.

NOTE:

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 REMOVAL AND INSTALLATION .

-- If equipped, remove the Fuel Pump Control Module -J538- -2- from the cover -1-.

Fig 1: Identifying Cover With Fuel Pump Control Module J538

GWWN20-0603

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Unclip the locking flange cover -1- at the tabs -arrows- using the Trim Removal Wedge 3409.

Fig 2: Identifying Right Cover

GWWA20-10835

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the connector -arrow-.

Fig 3: Fuel Pump Control Module Connector

GWWN20-10623

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 4: Fuel Lines At Flange

GWWN20-10624

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

If the vehicle has an auxiliary heater, then disconnect the connector and the fuel line from the Metering Pump -V54-.

-- Open the locking ring using Wrench - Fuel Sending Unit T10202 and lift the flange slightly.

Fig 5: Identifying Locking Ring And Wrench T10202

GWWN20-10625

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Carefully lift the fuel delivery unit flange -3-.

Fig 6: Identifying Fuel Delivery Unit Flange

GWWA20-11013

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the seal -1- and carefully raise the flange on the fuel delivery unit higher.

-- Attach the Fuel Extractor Unit Ground (GND) cable to an ungrounded area on the body.

-- Insert the suction hose for the Fuel Siphoning Device VAS 5190 as deep as possible into the fuel tank.

-- Extract the fuel using the Fuel Extractor Unit VAS 5190.

If the fuel tank was just drained, then reinstall the fuel delivery unit. Refer to FUEL DELIVERY UNIT .

Tightening Specifications

Refer to OVERVIEW - FUEL TANK