Volkswagen CC 2012 Instruction manual

Workshop Manual
CC 2012 ➤
Passat 2011 ➤
Passat Variant 2011 ➤
Fuel supply system, petrol engines
Engine ID CKM
ABWS CCZ B
CCT
A
CBF
A
CDA
A
CDA
B
CNN
A
CAV
D
CTH
D
CZD
A
Edition 05.2019
Service
Service Department. Technical Information

List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
20 - Fuel supply system
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2019 Volkswagen AG, Wolfsburg D3E803AE08C

Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety regulations for working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety precautions when using testers and measuring instruments during a road test . . . . 1
1.3 Safety precautions when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 2
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Rules for cleanliness when working on auxiliary/supplementary heater and fuel system . . 4
4 Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.1 Routing and attaching lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.2 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1 Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2 Fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.1 Assembly overview - fuel delivery unit/fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.2 Removing and installing fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . 43
3 Plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.1 Separating plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5 Activated charcoal filter with fuel tank leak detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.1 Assembly overview – activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.2 Removing and installing activated charcoal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.3 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6 Activated charcoal filter without fuel tank leak detection . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6.1 Assembly overview – activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6.2 Removing and installing activated charcoal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6.3 Checking fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
7 Accelerator pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
7.1 Assembly overview - accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
7.2 Removing and installing accelerator pedal module GX2 . . . . . . . . . . . . . . . . . . . . . . . . . . 70
8 Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
8.1 Checking fuel system pressurisation pump G6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
8.2 Removing and installing suction-jet pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
9 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
9.1 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
9.2 Removing and installing fuel gauge sender 2 G169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
Fuel supply system, petrol engines - Edition 05.2019
Contents i

CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
Fuel supply system, petrol engines - Edition 05.2019
ii Contents

00 – Technical data
1 Safety information
(VRL013019; Edition 05.2019)
⇒ “1.1 Safety regulations for working on fuel supply”, page 1
⇒ “1.2 Safety precautions when using testers and measuring in‐
struments during a road test”, page 1
⇒ “1.3 Safety precautions when working on vehicles with a start/
stop system”, page 2
1.1 Safety regulations for working on fuel supply
Risk of injury from highly pressurised fuel.
The fuel system is pressurised. Injury from fuel spray possible.
Before opening the fuel system:
– Wear protective goggles.
– Wear protective gloves.
– To release pressure, wrap a clean cloth around the connection
and carefully loosen the connection.
Danger of fire caused by escaping fuel
When the battery is connected and the driver door opens, the door
contact switch activates the fuel pump. Escaping fuel can ignite
and cause a fire.
– Disconnect voltage supply to fuel pump before opening the
fuel system.
NOTICE
Risk of irreparable damage to fuel pump if allowed to run dry.
– Never allow fuel pump to run »dry«.
1.2 Safety precautions when using testers and measuring instruments during
a road test
Risk of injury caused by unsecured testing and measuring instru‐
ments
When the front passenger airbag is triggered in an accident, in‐
sufficiently secured testing and measuring instruments become
dangerous projectiles.
– Secure testing and measuring instruments on the rear seat.
or
– Have a second person operate the test and measuring equip‐
ment on the rear seat.
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
Fuel supply system, petrol engines - Edition 05.2019
1. Safety information 1

1.3 Safety precautions when working on vehicles with a start/stop system
Risk of injury from engine starting unexpectedly
If the vehicle's start/stop system is activated, the engine can start
unexpectedly. A message in the dash panel insert indicates
whether the start/stop system is activated.
– Deactivate start/stop system by switching off the ignition.
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
Fuel supply system, petrol engines - Edition 05.2019
2 Rep. gr.00 - Technical data

2 Identification
⇒ “2.1 Engine number/engine data”, page 3
2.1 Engine number/engine data
Codes CKMA CAVD CTHD CZDA CCZB CDAA
Exhaust emission standard EU 5 EU 5 EU 5 EU 6 EU 5 EU 5
Displace‐
ment
l 1.4 1.4 1.4 1.4 2.0 1.8
Power kW 118 118 118 110 155 118
RON Bioethanol
E851) or su‐
per unlea‐
ded RON
95
Super un‐
leaded
RON 95
95 unlea‐
ded
Super un‐
leaded
RON 95
Super un‐
leaded
RON 95
Super un‐
leaded
RON 95
1) E85 means that up to 85% bioethanol may be contained in the
fuel. Any mixture ratio below 85% is permissible.
Codes CDAB CBFA CCTA BWS CNNA
Exhaust emission standard EU 4 SULEV3) ULEV 24) EU 5 ULEV 24)
Displacement l 1.8 2.0 2.0 3.6 3.6
Power kW 112 147 147 220 206
RON Super unlea‐
ded RON 95
Super unlea‐
ded RON 95
Super unlea‐
ded RON 95
98 unlea‐
ded2)
98 unlea‐
ded2)
1) E85 means that up to 85% bioethanol may be contained in the
fuel. Any mixture ratio below 85% is permissible.
2) In exceptional circumstances min. 95 RON, however with re‐
duced performance.
3) Super Ultra Low Emission Vehicle
4) Ultra Low Emission Vehicle
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
Fuel supply system, petrol engines - Edition 05.2019
2. Identification 3

3 General information
⇒ “3.1 Rules for cleanliness when working on auxiliary/supple‐
mentary heater and fuel system”, page 4
3.1 Rules for cleanliness when working on
auxiliary/supplementary heater and fuel
system
When working on the fuel supply and injection system, pay careful
attention to the following “rules”:
♦ Thoroughly clean all unions and adjacent areas before dis‐
connecting.
♦ Place removed parts on a clean surface and cover them over.
Use lint-free cloths only.
♦ Carefully cover opened components or seal them if repairs
cannot be carried out immediately.
♦ Install only clean parts; do not remove new parts from pack‐
aging until immediately before installing. Do not use parts that
have been kept unpackaged (for example in toolboxes).
♦ When the system is open: Do not work with compressed air.
♦ Do not move the vehicle.
♦ Immediately seal open lines and unions with clean plugs, for
example from engine bung set - VAS 6122- .
♦ Protect disconnected electrical connectors from dirt and water,
and reconnect them only when dry.
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
Fuel supply system, petrol engines - Edition 05.2019
4 Rep. gr.00 - Technical data

4 Repair notes
⇒ “4.1 Routing and attaching lines”, page 5
⇒ “4.2 General repair instructions”, page 5
4.1 Routing and attaching lines
Danger of damage to lines
Lines may become damaged from moving or hot components.
– Route lines in their original positions.
– Make sure there is sufficient clearance to moving or hot com‐
ponents.
♦ To prevent interchanging and to ensure that original installa‐
tion position is restored. For example, mark lines for fuel,
vacuum, activated charcoal filter system or electrical wiring
before they are removed. Where necessary, make sketches
or take photographs.
4.2 General repair instructions
Before starting work on the fuel supply system, the following steps
must be performed:
♦ Before starting work, the extraction hose of a switched-on ex‐
haust gas extraction system must be laid near to the assembly
opening of the fuel tank.
♦ It is used to extract fuel fumes.
♦ If no exhaust gas extraction system is available, a radial fan
with a displacement greater than 15 m3/h can be used provid‐
ing that motor is not in air flow.
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
♦ Interrupt power supply to fuel system pressurisation pump -
G6- ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations.
♦ Drain fuel tank ⇒ “1.2 Emptying fuel tank”, page 14 .
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
Fuel supply system, petrol engines - Edition 05.2019
4. Repair notes 5

20 – Fuel supply system
1 Fuel
⇒ “1.1 Assembly overview - fuel tank”, page 6
⇒ “1.2 Emptying fuel tank”, page 14
⇒ “1.3 Removing and installing fuel tank”, page 26
1.1 Assembly overview - fuel tank
⇒ “1.1.1 Assembly overview - fuel tank, vehicles with front-wheel
drive”, page 6
⇒ “1.1.2 Assembly overview - fuel tank, vehicles with front-wheel
drive with engine codes CBFA, CCTA, CNNA”, page 8
⇒ “1.1.3 Assembly overview - fuel tank, vehicles with four-wheel
drive”, page 10
⇒ “1.1.4 Assembly overview - fuel tank, vehicles with four-wheel
drive with engine code CNNA”, page 12
1.1.1 Assembly overview - fuel tank, vehicles with front-wheel drive
1 - Fuel line
❑Ensure firm seating
2 - Cap
❑ Renew if damaged
3 - Securing bolt
4 - Tank flap unit
❑ With rubber cup.
❑ Removing and installing
⇒ General body repairs,
exterior; Rep. gr. 55 ;
Tank flap unit; Remov‐
ing and installing fuel
tank flap unit .
5 - Breather line
❑ Clipped onto fuel tank
❑ Ensure firm seating
6 - Earth connection
❑ Ensure firm seating
7 - Fuel
❑ Removing and installing
⇒ page 26
❑Emptying ⇒ page 14
8 - Securing straps
❑Use suitable workshop
equipment to prevent
the securing straps from
turning while tightening
the bolts.
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
Fuel supply system, petrol engines - Edition 05.2019
6 Rep. gr.20 - Fuel supply system

9 - Heat shield
10 - Clamping washer
11 - Bolt
❑ Renew after removal
❑ 25 Nm
12 - Seal
❑ Renew after removal
❑ When installing, fit dry in fuel tank opening.
❑ Moisten with fuel only when installing flange.
13 - Fuel delivery unit
❑ Removing and installing ⇒ page 43
❑ Checking fuel pump ⇒ page 73 .
❑ With fuel gauge sender - G-
❑ Removing and installing fuel gauge sender - G- ⇒ page 111
❑ Clean strainer if soiled
❑ Note installation position ⇒ page 42
14 - Suction-jet pump
15 - Flange with fuel filter
❑ With 6 bar pressure relief valve
❑ Note installation position ⇒ page 42
❑ Can be disconnected from fuel delivery unit ⇒ page 46 .
16 - Locking ring
❑ Remove and install using wrench - T10202- .
❑ Ensure firm seating
❑ 110 Nm
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
Fuel supply system, petrol engines - Edition 05.2019
1. Fuel 7

1.1.2 Assembly overview - fuel tank, vehicles with front-wheel drive with engine
codes CBFA, CCTA, CNNA
1 - Fuel line
❑Ensure firm seating
2 - Cap
❑ Renew if damaged
3 - Securing bolt
4 - Tank flap unit
❑ With rubber cup.
❑ Removing and installing
⇒ General body repairs,
exterior; Rep. gr. 55 ;
Tank flap unit; Remov‐
ing and installing fuel
tank flap unit .
5 - Breather line
❑ Clipped onto fuel tank
❑ Ensure firm seating
6 - Vacuum line
❑ Clipped onto fuel tank
❑ Ensure firm seating
7 - Earth connection
❑ To protective plate for
filler neck.
❑ Ensure firm seating
8 - Earth connection
❑ Ensure firm seating
❑ Ensure good contact to
body.
9 - Clip
10 - Fuel
❑ Emptying ⇒ page 14
❑Removing and installing ⇒ page 26
❑When removing, support using engine and gearbox jack - V.A.G 1383 A- .
11 - Securing straps
❑ Use suitable workshop equipment to prevent the securing straps from turning while tightening the bolts.
12 - Heat shield
13 - Clamping washer
14 - Bolt
❑ Renew after removal
❑ 25 Nm
15 - Seal
❑ Renew after removal
❑ When installing, fit dry in fuel tank opening.
❑ Moisten with fuel only when installing flange.
16 - Fuel delivery unit
❑ Removing and installing ⇒ page 41
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
Fuel supply system, petrol engines - Edition 05.2019
8 Rep. gr.20 - Fuel supply system

❑ Checking fuel pump ⇒ page 73 .
❑ Removing and installing fuel gauge sender - G- ⇒ page 111
❑ Clean strainer if soiled
❑ Note installation position ⇒ page 42
17 - Pop rivet
18 - Protective plate
❑ For filler neck.
19 - Suction-jet pump
❑ Removing and installing ⇒ page 106
20 - Flange with fuel filter
❑ With 6.2 bar pressure relief valve
❑ Removing and installing ⇒ page 41
❑ Observe installation position
❑ Can be disconnected from fuel delivery unit ⇒ page 46 .
21 - Locking ring
❑ Ensure firm seating
❑ Remove and install using wrench - T10202- .
❑ 110 Nm
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
Fuel supply system, petrol engines - Edition 05.2019
1. Fuel 9

1.1.3 Assembly overview - fuel tank, vehicles with four-wheel drive
1 - Supply line
❑Clipped onto fuel tank
❑ Ensure firm seating
2 - Locking ring
❑ Ensure firm seating
❑ Remove and install us‐
ing wrench - T10202- .
❑ 110 Nm
3 - Cap
❑ Renew if damaged
4 - Securing bolt
❑ 1.5 Nm
5 - Tank flap unit
❑ With rubber cup.
❑ Removing and installing
⇒ General body repairs,
exterior; Rep. gr. 55 ;
Tank flap unit; Remov‐
ing and installing fuel
tank flap unit .
6 - Bolt
❑ 10 Nm
7 - Earth connection
❑ Ensure firm seating
8 - Pressure retention valve
with connecting hose
❑ To remove, grasp se‐
curing ring (grey) and
pull off upwards.
❑ Ensure firm seating
❑ From activated charcoal
filter
9 - Breather line
❑ Clipped onto fuel tank
❑ Ensure firm seating
❑ From activated charcoal filter
10 - Suction-jet pump
❑ Clipped onto fuel gauge sender 2 - G169-
❑ Removing and installing ⇒ page 106
11 - Bolt
❑Renew after removal
❑ 25 Nm
12 - Seal
❑ Renew after removal
❑ When installing, fit dry in fuel tank opening.
❑ Moisten with fuel only when installing flange.
13 - Fuel gauge sender 2 - G169-
❑ Note installation position on fuel tank ⇒ page 42
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
Fuel supply system, petrol engines - Edition 05.2019
10 Rep. gr.20 - Fuel supply system

❑ Removing and installing ⇒ “9.2 Removing and installing fuel gauge sender 2 G169 ”, page 112
14 - Fuel
❑ Emptying ⇒ “1.2 Emptying fuel tank”, page 14
❑ Removing and installing
⇒ “1.3.2 Removing and installing fuel tank - vehicles with four-wheel drive”, page 31
15 - Heat shield
❑ Bolted with clamping washers.
16 - Bolt
❑ Renew after removal
❑ 25 Nm
17 - Securing straps
❑ Use suitable workshop equipment to prevent the securing straps from turning while tightening the bolts.
18 - Breather line
❑ Clipped onto fuel tank
❑ Ensure firm seating
❑ To activated charcoal filter solenoid valve 1 - N80-
19 - Fuel delivery unit
❑ Removing and installing ⇒ page 43
❑ If fuel delivery unit was renewed, adapt engine control unit to fuel pump ⇒ Vehicle diagnostic tester
“Guided function”
❑ Checking fuel pump ⇒ page 73 .
❑ With fuel gauge sender - G-
❑ Removing and installing fuel gauge sender - G- ⇒ page 111
❑ Clean strainer if soiled
20 - Flange with fuel filter
❑ With 6.2 bar pressure relief valve
❑ Note installation position on fuel tank ⇒ page 42
❑ Removing and installing ⇒ page 43
❑ Can be disconnected from fuel delivery unit ⇒ page 46 .
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
Fuel supply system, petrol engines - Edition 05.2019
1. Fuel 11

1.1.4 Assembly overview - fuel tank, vehicles with four-wheel drive with engine
code CNNA
1 - Supply line
❑ Clipped onto fuel tank
❑ Ensure firm seating
2 - Locking ring
❑ Ensure firm seating
❑ Remove and install us‐
ing wrench - T10202- .
❑ 110 Nm
3 - Cap
❑ Renew if damaged
4 - Securing bolt
❑ 1.5 Nm
5 - Tank flap unit
❑ With rubber cup.
❑ Removing and installing
⇒ General body repairs,
exterior; Rep. gr. 55 ;
Tank flap unit; Remov‐
ing and installing fuel
tank flap unit .
6 - Breather line
❑ Clipped onto fuel tank
❑ Ensure firm seating
7 - Vacuum line
❑ Clipped onto fuel tank
❑ Ensure firm seating
8 - Earth connection
❑ To protective plate for
filler neck.
❑ Ensure firm seating
❑ Fitting position ⇒ page 26
9 - Earth connection
❑ Ensure firm seating
❑ Ensure good contact to body
❑ Fitting position ⇒ page 26
10 - Clip
11 - Suction-jet pump
❑ Clipped onto fuel gauge sender 2 - G169-
❑ Removing and installing ⇒ page 106
12 - Bolt
❑ Renew after removal
❑ 25 Nm
13 - Seal
❑ When installing, fit dry in fuel tank opening.
❑ Moisten with fuel only when installing flange.
❑ Renew after removal
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
Fuel supply system, petrol engines - Edition 05.2019
12 Rep. gr.20 - Fuel supply system

14 - Fuel gauge sender 2 - G169-
❑Note installation position on fuel tank ⇒ page 112
❑Removing and installing ⇒ page 112
15 - Fuel
❑Emptying ⇒ page 14
❑Removing and installing ⇒ page 31
16 - Heat shield
❑Bolted with clamping washers.
17 - Bolt
❑ Securing bolt of tensioning strap, heat shield and mounting for middle silencer. Secure support for centre
silencer to body ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Assembly overview - silencers
❑ Renew after removal
❑ 25 Nm
18 - Securing straps
❑ Use suitable workshop equipment to prevent the securing straps from turning while tightening the bolts.
19 - Protective plate
❑ For filler neck.
20 - Fuel delivery unit
❑ Removing and installing ⇒ page 43
❑ If fuel pump unit was renewed, adapt engine control unit to fuel pump ⇒ Vehicle diagnostic tester “Guided
functions”.
❑ Checking fuel pump ⇒ page 73 .
❑With fuel gauge sender - G-
❑ Removing and installing fuel gauge sender - G- ⇒ page 111
❑Note installation position ⇒ page 42
❑Clean strainer if soiled
21 - Rivets
22 - Flange with fuel filter
❑ With 6.2 bar pressure relief valve
❑ Removing and installing ⇒ page 43
❑Note installation position ⇒ page 42
❑Can be disconnected from fuel delivery unit ⇒ page 46 .
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
Fuel supply system, petrol engines - Edition 05.2019
1. Fuel 13

1.2 Emptying fuel tank
⇒ “1.2.1 Emptying fuel tank when fuel pump is intact”,
page 14 .
⇒ “1.2.2 Emptying fuel tank if it is more than 3/4 full”, page 17 .
⇒ “1.2.3 Emptying fuel tank with fuel tank less than 3/4 full, vehi‐
cles with front-wheel drive”, page 18
⇒ “1.2.4 Emptying fuel tank with fuel tank less than 3/4 full, vehi‐
cles with four-wheel drive”, page 21 .
1.2.1 Emptying fuel tank when fuel pump is intact
Special tools and workshop
equipment required
♦ Removal wedge - 3409-
♦ Remote control - V.A.G 1348/3A-
♦ Test instrument adapter/DSO (5-pin) - VAS 5565-
♦ Fuel extractor - VAS 5190-
♦ Fuel extractor - VAS 5190 A- for E 85 fuel (not shown).
♦ Adapter for fuel extraction - VAS 5190-
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
Fuel supply system, petrol engines - Edition 05.2019
14 Rep. gr.20 - Fuel supply system

Note
If the fuel extraction unit - VAS 5190- is still fitted with the extrac‐
tion hose with a fixed tip, the extraction hose must be replaced
with the version with a screw-in tip.
– Pull off supply line (metal connector) -1-. Separate plug-in
connectors
⇒ “3.1 Separating plug-in connectors”, page 51 .
– Collect escaping fuel with a cleaning cloth.
– Connect fuel extractor - VAS 5190- with adapter for fuel ex‐
tractor - VAS 5190 /3- to fuel supply line.
CAUTION
Risk of fire due to escaping fuel.
Risk of severe injuries and burns.
– Check all connected lines for secure fit by pulling.
– Take any fuel-soaked cloths away from area of vehicle.
– Secure earth wire of fuel extractor to a bare metal part of the
body.
– Remove bench seat or fold it upwards ⇒ General body repairs,
interior; Rep. gr. 72 ; Rear seat; Removing and installing
bench seat / individual seats .
– Guide carpet out and fold upwards, if fitted.
– Remove right cover with fuel pump control unit - J538- -2- from
assembly opening above fuel delivery unit.
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
Fuel supply system, petrol engines - Edition 05.2019
1. Fuel 15

– To do this, unclip right cover -1- at retaining tabs -arrows- using
removal wedge - 3409- .
Vehicles with auxiliary heater
– Remove connector -1- from cover -3-.
– Release connectors -1- and pull off.
– Unclip sealing grommet -2- downwards from cover -3-.
– Guide wiring harness out downwards.
– Release and pull fuel delivery line -2- from flange -1-. Separate
plug-in connectors ⇒ page 51 .
Continued for all vehicles
– Pull connector -1- off flange -3-.
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
Fuel supply system, petrol engines - Edition 05.2019
16 Rep. gr.20 - Fuel supply system