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
11 - Securing straps
12 - Heat shield
13 - Clamping washer
14 - 25 Nm
❑ Renew
❑ To secure the securing straps for the fuel tank, only bolts with loose washers must be used. If different
bolts are used, the securing straps might twist during tightening. Bolts ⇒ ETKA (Electronic parts cata‐
logue) .
15 - Seal
❑ Renew
❑ When installing, fit dry in fuel tank opening.
❑ Moisten with fuel only when installing flange.
16 - Fuel delivery unit
❑ Removing and installing ⇒ page 326
❑ Checking fuel pump ⇒ page 331 .
❑ Removing and installing fuel gauge sender - G- ⇒ page 330
❑ Clean strainer if soiled
17 - Pop rivet
18 - Protective plate
❑ For filler neck.
19 - Suction-jet pump
20 - Flange with fuel filter
❑ With 6.2 bar pressure relief valve
❑ Removing and installing ⇒ page 326
21 - Locking ring 110 Nm
❑ Ensure firm seating
❑ Remove and install using wrench - T10202- .
3.3
Emptying fuel tank
Special tools and workshop equipment required
♦ Fuel extractor - VAS 5190-
3. Fuel tank (Passat, CC)
283
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
♦ Special wrench - T10202-
♦ Torque wrench (40 to 200 Nm) - V.A.G 1332-
– Note safety precautions before beginning work ⇒ page 278 .
3
Emptying fuel tank if more than / full ⇒ page 286
4
3
Emptying fuel tank if less than / full ⇒ page 286
4
3.3.1
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 cable to 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.
284
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
– 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 .
– Remove cover -1- with fuel pump control unit - J538- -2- from
fuel delivery unit.
– Pull connector -A- off fuel delivery unit flange.
– Connect test instrument adapter/DSO (5-pin) - VAS 5565- to
connector and fuel delivery unit.
– Connect remote control - V.A.G 1348/3A- to adapter - 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«.
3. Fuel tank (Passat, CC)
285
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
3.3.2
Emptying fuel tank if it is more than 3/
4
full
Caution
Secure earth wire of fuel extractor - VAS 5190- to a bare metal
part of the body.
– Use insulating tape to mark the extraction hose -arrow- at a
distance of -a- = 990 mm from the end of the hose.
– Remove filler cap from fuel tank filler neck.
– Push extraction hose into fuel tank until marking on hose co‐
incides with filler neck.
Note
♦ The shaft piece -1- is not used.
♦ There is a flap on the lower end of the fuel filler neck in the fuel
tank which must not be damaged by the extraction hose.
Therefore, only push the hose in as far as the marking.
– 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.
3.3.3
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 .
– 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.
286
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
– Release connector -1- and fuel line -2- and pull them off flange
-3-.
Note
♦ Press in securing ring to release fuel line.
♦ 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- .
Caution
Do not cant key - T10202- and press against locking ring firmly.
If the key slips off, the fuel delivery unit can be damaged.
– Lift sender flange.
– 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 326 .
3.4
Removing and installing fuel tank
Special tools and workshop equipment required
♦ Torque wrench (5 to 50 Nm) - V.A.G 1331-
Install fuel tank ⇒ page 290 .
3.4.1
Removing fuel tank
Note
♦ The rear axle must be lowered to remove the fuel tank.
♦ Note safety precautions before beginning work ⇒ page 278 .
♦ Observe rules for cleanliness ⇒ page 280 .
♦ Assembly overview - fuel tank ⇒ page 281 .
3. Fuel tank (Passat, CC)
287
2024 VW Passat Owner's Manual
VW Passat B7 Service & Repair Manual
VW Passat B6 Service & Repair Manual
