Emptying fuel tank when less then 3/4 full, vehicles with four-wheel drive — VW

🧭 Before you start

Fits: VW Passat B8 (3G, 2014–)

• Opens: fuel

🔧 Engine codes this applies to

📋 Procedure

1. Draining fuel tank
2. Remove rear bench seat General body repairs, interior72Rear seat; Removing and installing bench seat / individual seats.
3. Unclip cover (1) for flange on right at retaining tabs (arrows), using removal wedge3409.
4. Unclip sealing grommet (1) downwards from cover (2).
5. Push cover (2) back along wiring harness (3).

6. Release and pull off connectors (1) and (2) on sealing flange.
7. Detach connector (3) for metering pump V54 from sealing flange.
8. Release and pull off connector (3) for metering pump V54.
9. Push tab (2) upwards in (direction of arrow A).
10. To do this, reach in with your finger between floor panel and fuel tank.
11. 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).
12. Guide fuel pump control unit J538 out towards interior between fuel tank and floor panel.
13. Place fuel pump control unit J538 and wiring harness to one side.
14. Disconnect fuel line (1) on sealing flange. Separate plug-in connectors .
15. Disconnect fuel return line (2) on sealing flange. Separate plug-in connectors .
16. Remove fuel line (3) leading to metering pump V54 for auxiliary heater from sealing flange.
17. To do this, open clip at bottom.
18. Carefully pull out fuel line (3).
19. Open locking ring using fuel tank sender unit tool T10202.
20. Carefully lift flange of fuel delivery unit (3).
21. Remove gasket (1) and carefully lift up the flange of the fuel delivery unit slightly more.
22. Secure earth wire of fuel extractor to a bare metal part of the body.
23. Insert suction hose of fuel extractorVAS 5190 as far as possible into fuel tank.
24. Extract fuel using fuel extractorVAS 5190.
25. Unclip cover (1) for sealing flange on left from retaining tabs (arrows) using removal wedge3409.
26. Unclip sealing grommet (1) downwards from cover (2).
27. Push cover (2) back along wiring harness (3).
28. Release and pull off electrical connectors (1) to (3).
29. Unclip connectors (1) and (2) from flange.
30. Open locking ring using fuel tank sender unit tool T10202.
31. Carefully pull sealing flange (3) on left together with suction-jet pump (1) a short distance out of opening in fuel tank.
32. Insert suction hose of fuel extractorVAS 5190 as far as possible into fuel tank.
33. Extract fuel using fuel extractorVAS 5190.
34. Install fuel delivery unit .
35. Install fuel gauge sender 2G169.

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