Fuel Tank, Draining When Less Than 3/4 Full, Fwd [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]

WARNING: This page is about a different car, the 2023 Volkswagen Arteon. However, it is still accessible from the selected car via links, so may be relevant.

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.

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

Passat and Arteon:

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

Tiguan:

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

Continuation for All Vehicles:

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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 .

Fig 3: Fuel Lines to the Fuel Delivery Unit

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

CAUTION:

The fuel system is under pressure.

Risk of injury from fuel spraying out.

- Wear protective eyewear.

- Wear safety gloves.

- Reduce the pressure: place clean cloths around the connection point and carefully open the connection point.

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 using the Wrench - Fuel Sending Unit:T10202 .

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

Fig 5: Identifying Fuel Delivery Unit Flange

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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 .

If the fuel tank was only emptied: Re-install the fuel delivery unit. Refer to FUEL DELIVERY UNIT/FUEL LEVEL SENSOR, REMOVING AND INSTALLING .

Tightening Specifications

Refer to OVERVIEW - FUEL DELIVERY UNIT/FUEL LEVEL SENSOR
Refer to the appropriate Service Information .