Volkswagen Golf Service & Repair Manual: Emptying fuel tank if it is less than 3/4 full

Special tools and workshop equipment required

Removal wedge -3409-

Wrench -T10202-

Torque wrench -V.A.G 1332-

Fuel extractor -VAS 5190-

Fuel extractor -VAS 5190 A- for E 85 fuel (not shown).

Note

To extract E 85 fuel, use only fuel extractor -VAS 5190 A-!

Observe safety precautions → Chapter.
Observe rules for cleanliness → Chapter.
Secure earth wire of fuel extractor to a bare metal part of the body.

Golf SV:

Remove right rear seat → General body repairs, interior; Rep. gr.72.

Partially detach cover -1- in floor covering at parting line -arrow-.
Do not detach cover completely from floor covering in order to ensure it is reinstalled in the correct installation position.
Detach it just enough that the cover can be folded upwards.
Fold up cover in -direction of arrow-.

Golf and Golf Estate:

Remove rear bench seat → General body repairs, interior; Rep. gr.72.

Continuation for all vehicles:

Unclip cover -1- for flange at retaining tabs -arrows-, using removal wedge -3409-.

Unclip sealing grommet -1- downwards from cover -2-.
Push cover -2- back along wiring harness -3-.

Release and pull off connector -1- on sealing flange.
If fitted, detach connector -2- for metering pump -V54- of auxiliary heater on sealing flange and lay connector aside.

Push tab -2- upwards in -direction of arrow A-.
To do this, reach in with your finger between floor panel and fuel tank.
At the same time, carefully pull fuel pump control unit -J538--1- out of mounting -in direction of arrow B- by grasping hold of wiring harness -3-.
Guide fuel pump control unit -J538- out towards interior between fuel tank and floor panel.
Place fuel pump control unit -J538- together with wiring harness to one side.

Disconnect fuel line -1- on sealing flange. Separate plug-in connectors → Chapter.

The fuel system is pressurised.Risk of injury due to fuel which may spurt out.Wear eye protection.Wear protective gloves.Release pressure: place clean cloth around connection and carefully open connection.

If fitted, remove fuel line -2- leading to metering pump -V54- for auxiliary heater from sealing flange.
To do this, loosen lower hose clip.

Open locking ring using wrench -T10202-.

Carefully lift flange of fuel delivery unit -3-.
Remove gasket -1- and carefully lift up the flange of the fuel delivery unit slightly more.
Secure earth wire of fuel extractor to a bare metal part of the body.
Insert suction hose of fuel extractor -VAS 5190- as far as possible into fuel tank.
Extract fuel using fuel extractor -VAS 5190-.

If the fuel tank needs only to be emptied, reinstall fuel delivery unit → Chapter.

Emptying fuel tank if it is less than 3/4 full