Fuel Tank, Draining When Less Than 3/4 Full, AWD [CZCA, CZEA, CJSA, CJSC, CHHB, CJXA, CWLA, CZDA, CZPA, CXDA, DJHC, CZPB, Dada, DLRB, DJVA, DACB, DKTA, DKZA, DNUA, DPBE, DPCA, CZDE, CZDB, DNFG, DNFE, DNNA, DNPA, DSFE, DUNA, DRFA, DSFB, DXDB]

Special tools and workshop equipment required 

• Wrench - Fuel Sending Unit:T10202 
  Fig 1: Identifying Wrench - Fuel Sending Unit

  Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
• Fuel Extractor:VAS 5190A 
  Fig 2: Fuel Extraction Device VAS5190A

  Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Drain the fuel tank. Refer to FUEL TANK, DRAINING .

-- Remove the right and left installation opening cover. Refer to INSTALLATION OPENING COVER, REMOVING AND INSTALLING .

-- Unlock and disconnect the connectors -1- and -2- from the sealing flange.

Fig 3: Top View Of Fuel Pump

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Vehicles with Parking Heater:

-- Release the connector -3- for the Metering Pump -V54- and disengage it from the sealing flange.

-- Release the connector -3- for the Metering Pump -V54- and remove it.

Continuation for All Vehicles:

-- Remove the Fuel Pump Control Module -J538-. Refer to Fuel Pump Control Module -J538-, REMOVING AND INSTALLING .

-- Remove the Fuel Pump Control Module -J538- together with the wiring harness and move to the side.

-- Remove the fuel line -1- from the sealing flange. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the fuel return line -2- from the sealing flange. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

Vehicles with Parking Heater:

-- Remove the fuel line -3- to the Metering Pump -V54- for the parking heater on the sealing flange. Refer to PARKING/AUXILIARY HEATER FUEL LINE, REMOVING AND INSTALLING .

Continuation for All Vehicles:

Fig 4: Identifying Fuel Sending Unit Wrench

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Open the locking ring with Wrench - Fuel Sending Unit:T10202  .

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

Fig 5: Identifying Fuel Delivery Unit Flange

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-- Remove the seal -1- and slightly lift the fuel delivery unit flange again carefully.

-- Attach the ground wire of the Fuel Extractor Unit to a bare area on the body.

-- Insert the suction hose for the Fuel Extractor:VAS 5190A  as deep as possible into the fuel tank.

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

-- Unlock and disconnect the connectors -2- from the sealing flange.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Unlock and disconnect the connector -1- from the sealing flange.

-- If equipped, release and disconnect the connector -3- on the sealing flange.

-- Unclip the connectors from the sealing flange mounts.

-- Open the locking ring with Wrench - Fuel Sending Unit:T10202  .

Fig 6: Identifying Fuel Sending Unit Wrench

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Carefully remove the sealing flange -3- on the left side together with the suction jet pump -1- a little from the fuel tank opening.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Insert the suction hose for the Fuel Extractor:VAS 5190A  as deep as possible into the fuel tank.

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

If the fuel tank is only emptied:

-- Re-install the fuel delivery unit. Refer to FUEL DELIVERY UNIT/FUEL LEVEL SENSOR, REMOVING AND INSTALLING .

-- Reinstall the Fuel Level Sensor 2 -G169-. Refer to Fuel Level Sensor 2 -G169-, REMOVING AND INSTALLING .

Tightening Specifications

• Refer to OVERVIEW - FUEL DELIVERY UNIT/FUEL LEVEL SENSOR 
• Refer to Fuel Level Sensor 2 -G169-, REMOVING AND INSTALLING 
• Refer to the appropriate Service Information .