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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‐

ing Conditions”, page 4

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‐

stalling”, page 52

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

/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-