Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 745
Note
Use only the -VAS5190A- when extracting E 85 - fuel!
– Pay attention to all safety precautions. Refer to
⇒ “1 Safety Precautions”, page 1
.
– Follow the guidelines for clean working conditions. Refer to
⇒ “3.1 Parking/Auxiliary Heater and Fuel System Clean Work‐
Golf Sportsvan:
– Remove the right rear seat. Refer to ⇒ Body Interior; Rep. Gr.
72 ; Rear Seats; Bench Seat / Single Seat, Removing and In‐
stalling .
– Partially loosen the cover -1- in the carpet at the separating
line -arrow-.
– Do not separate the cover completely from the carpet so that
later it will be installed correctly.
– Only loosen so far that the cover can be folded up.
– Fold up the cover in the direction of the -arrow-.
Golf and Golf Wagon:
– Remove the rear bench seat. Refer to ⇒ Body Interior; Rep.
Gr. 72 ; Rear Seats; Bench Seat / Single Seats, Removing
and Installing .
Continuation for All Vehicles:
– Unclip the sealing flange cover -1- at the tabs -arrows- using
the -3409- .
– Unclip the grommet -1- downward out of the cover -2-.
– Guide the cover -2- on the wiring harness -3- toward the rear.
– Unlock and disconnect the connector -1- from the sealing
flange.
– If equipped, disengage the connector -2- for the parking heater
Metering Pump - V54- on the sealing flange and move it to the
side.
– Lift the tab -2- in the direction of the -arrow A-.
– To do so, reach a finger between the floor panel and the fuel
tank.
– At the same time, carefully pull the Fuel Pump Control Module
- J538- -1- out of the mount at the wiring harness -3- in the
direction of the -arrow B-.
– Remove the Fuel Pump Control Module - J538- toward the
inside between the fuel tank and the floor panel.
– Move the Fuel Pump Control Module - J538- together with the
wiring harness to the side.
– Remove the fuel line -1- from the sealing flange. Disconnect
the connector couplings. Refer to
⇒ “4.1 Connector Couplings, Disconnecting”, page 62
.
WARNING
The fuel line is under pressure.
Fuel poses a risk of injury to the eyes and skin.
Wear protective eyewear and protective clothing to avoid injury
and contact with skin. Place a cleaning cloth around the con‐
nection point before loosening hose connections. Carefully
open the connection point to release the pressure.
– If equipped, remove the fuel line -2- to the Metering Pump -
V54- for the parking heater on the sealing flange.
– Loosen the lower hose clamp to do this.
– Open the locking ring using the Wrench - Fuel Sending Unit -
T10202- .
– Carefully lift the fuel delivery unit flange -3-.
– Remove the seal -1- and slightly lift the fuel delivery unit flange
again carefully.
– Attach the ground wire of the -VAS5190- to a bare area on the
body.
– Insert the suction hose for the -VAS5190- as deep as possible
into the fuel tank.
– Extract the fuel using the -VAS5190- .
If the fuel tank only needs to be drained, reinstall the fuel delivery
unit. Refer to
⇒ “2.2 Fuel Delivery Unit/Fuel Level Sensor, Removing and In‐
Tightening Specifications
♦ Refer to
⇒ “2.1 Overview - Fuel Delivery Unit/Fuel Level Sensor”, page
♦ Refer to ⇒ Heating, Ventilation and Air Conditioning; Rep. Gr.
82 ; Fuel Supply; Component Location Overview - Fuel Sup‐
ply .
1.3.5
Fuel Tank less than
3
/4 Full, Emptying,
Vehicles with Engine Code CWVA
Special tools and workshop equipment required
♦ Trim Removal Wedge - 3409-
♦ Fuel Extractor VAS5190A - VAS5190-
♦ Fuel Extraction Unit - VAS5190 A- (not illustrated) for E 85 -
fuel.
♦ Wrench - Fuel Sending Unit - T10202-
♦ Torque Wrench 1332 40-200Nm - VAG1332-
Note
Use only the Fuel Extractor Unit - VAS5190 A- when extracting E
85 - fuel!
– Pay attention to all safety precautions. Refer to
⇒ “1 Safety Precautions”, page 1
– Follow the guidelines for clean working conditions. Refer to
⇒ “3.1 Parking/Auxiliary Heater and Fuel System Clean Work‐
.
Golf Sportsvan:
– Remove the right rear seat. Refer to ⇒ Body Interior; Rep. Gr.
72 ; Rear Seats; Bench Seat / Single Seat, Removing and In‐
stalling .
– Partially loosen the cover -1- in the carpet at the separating
line -arrow-.
– Do not separate the cover completely from the carpet so that
later it will be installed correctly.
– Only loosen so far that the cover can be folded up.
– Fold up the cover in the -direction of the arrow-.
Golf and Golf wagon:
– Remove the rear bench seat. Refer to ⇒ Body Interior; Rep.
Gr. 72 ; Rear Seats; Bench Seat / Single Seats, Removing
and Installing .
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