CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
Installation position of fuel delivery unit
•
Tab -2- on flange must be between lugs -1- and -3- on fuel
tank.
•
-Arrow- points in direction of travel.
Location of fuel filter
Pin -2- on filter housing must engage in notch of guide -1- on filter
bracket.
4.3
Draining fuel tank (engine codes BZB,
CAWA, CAWB, CGYA, CCZA, CCZB,
CDAA)
Special tools and workshop equipment required
♦ Fuel extractor - VAS 5190-
♦ Special wrench - T10202-
♦ Torque wrench (40 to 200 Nm) - V.A.G 1332-
4. Fuel tank (Golf, Scirocco)
295
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
– Note safety precautions before beginning work ⇒ page 278 .
3
Emptying fuel tank if more than / full ⇒ page 297
4
3
Emptying fuel tank if less than / full ⇒ page 298
4
4.3.1
Emptying fuel tank when fuel pump is
intact
Special tools and workshop equipment required
♦ Adapter for fuel extraction - VAS 5190 /3-
♦ Test instrument adapter/DSO (5-pin) - VAS 5565-
♦ Remote control - V.A.G 1348/3A-
WARNING
♦ Fuel supply line is pressurised. Wear protective goggles
and protective clothing to avoid injury and contact with the
skin. Wrap a cloth around the connection before loosening
hose connections. Then release pressure by carefully
pulling hose off connection.
♦ Connect fuel extractor - VAS 5190- earth wire to vehicle
earth.
– Pull off supply line (metal coupling) -arrow- and catch escaping
fuel with a cloth.
Note
Press in securing ring to release the fuel lines.
– Connect fuel extractor - VAS 5190- with adapter for fuel ex‐
tractor - VAS 5190 /3- to fuel supply line.
– Remove bench seat ⇒ General body repairs, interior; Rep. gr.
72 ; Removing and installing bench seat .
296
Rep. gr.20 - Fuel supply system
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
– Remove cover -1- with fuel pump control unit - J538- -2- from
fuel delivery unit.
– Pull off connector -arrow-.
– Connect test instrument adapter/DSO (5-pin) - VAS 5565- to
connector and fuel delivery unit.
– Connect remote control - V.A.G 1348/3A- to test instrument
adapter/DSO (5-pin) - VAS 5565- and to battery positive (+).
Note
This step serves only to have the fuel pump running when the
engine is stopped.
– Remove filler cap from fuel tank filler neck.
– Operate remote control - V.A.G 1348/3A- and shut-off tap on
fuel extractor - VAS 5190- until fuel tank is empty.
Caution
Do not allow the fuel pump run »dry«.
4.3.2
Emptying fuel tank if it is more than 3/
full
4
Caution
Secure earth wire of fuel extractor - VAS 5190- to a bare metal
part of the body.
4. Fuel tank (Golf, Scirocco)
297
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
– Remove cotter -2- from shaft -1- of fuel extractor - VAS 5190- .
– At a distance of -a- = 1180 mm from the end of the hose, mark
extraction hose with insulating tape -arrow-.
– Remove filler cap from fuel tank filler neck.
– Screw shaft end -1- of fuel extractor unit - VAS 5190- onto fuel
filler neck.
– Push extraction hose into fuel tank until marking on hose
-arrow- coincides with shaft end.
Note
A ball valve -2- is located at the bottom of the filler neck in the fuel
tank -1-; take care not to damage it with the extraction hose -3-.
Therefore push hose into filler neck only as far as marking
-arrow-.
– Drain fuel tank as much as possible through fuel filler neck.
– Carefully pull out extraction hose.
Note
♦ When no more fuel is extracted, the tank is emptied just
enough for the sender flange to be opened without danger.
The tank may be removed while containing remaining fuel.
4.3.3
Emptying fuel tank if it is less than 3/ full
4
– Remove bench seat ⇒ General body repairs, interior; Rep. gr.
72 ; Removing and installing bench seat .
298
Rep. gr.20 - Fuel supply system
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
– Remove cover -1- with fuel pump control unit - J538- -2- from
fuel delivery unit.
WARNING
Fuel supply line is pressurised. Wear protective goggles and
protective clothing to avoid injury and contact with the skin.
Wrap a cloth around the connection before loosening hose
connections. Then release pressure by carefully pulling hose
off connection.
– Pull off connector -arrow-.
– Pull fuel lines -1- and -2- off the flange.
Note
♦ Press in securing ring to release the fuel lines.
♦ On vehicles with auxiliary heater, the connector and the fuel
line of the metering pump - V54- must also be disconnected.
– Open locking ring using key - T10202- and raise flange slightly.
Caution
Do not cant key - T10202- and press against locking ring firmly.
If the key slips off, the fuel delivery unit can be damaged.
– Insert extraction hose of fuel extractor - VAS 5190- as deeply
as possible into fuel tank and extract fuel.
If fuel tank needed only to be emptied, reinstall sender flange
⇒ page 346 .
4.4
Emptying fuel tank (engine codes
CBFA, CCTA, CCTB)
Special tools and workshop equipment required
4. Fuel tank (Golf, Scirocco)
299
2024 VW Passat Owner's Manual
VW Passat B7 Service & Repair Manual
VW Passat B6 Service & Repair Manual
