Fuel Tank, Draining

Fuel Tank, Draining

Special tools, testers and auxiliary items required

• Fuel Extracting Device (VAS 5190)

• Wrench (T10202)

• Torque Wrench (40-200 Nm) (V.A.G 1332)

- Read the safety precautions before beginning work. Refer to => [ Safety Precautions ] Safety Precautions.

=> [ With Fuel Delivery Unit Installed ]

=> [ More than 3/4 Full ]

=> [ Less than 3/4 Full ]

With Fuel Delivery Unit Installed

Special tools, testers and auxiliary items required

• Fuel Extracting Adapter (VAS 5190/3)

• Test Instrument Adapter/DSO (5-pin) (VAS 5565)

• Remote Control (V.A.G 1348/3A)

CAUTION!
The fuel system is under pressure!

• Wear protective goggles and protective clothing to prevent injuries and contact with skin.

• Before disconnecting the connection, place a cloth around the connection point. Then release pressure by carefully disconnecting the connection.

• Connect the fuel extracting device (VAS 5190 ) ground strap to the vehicles ground strap.

- Disconnect the supply line (metal coupling) - arrow - and collect the leaking fuel in a cloth.





• Press in the securing ring to disengage the fuel line.

- Connect the (VAS 5190) using the (VAS 5190/3) to the fuel supply line.





- Remove the rear seat bench.

- Remove the cover - 1 - with the fuel pump control module (J538) - 2 - from the fuel delivery unit.





- Disconnect the 5 pin connector - arrow - from the fuel delivery unit.





- Install the (VAS 5565) between the connectors on the fuel delivery unit and cover.





- Connect the (V.A.G 1348/3A) to the (VAS 5565) and to the battery positive terminal.

• This step allows the fuel pump to run when the engine is not running.

- Remove the fuel filler cap from the fuel filler tube.

- Operate the (V.A.G 1348/3A) and the shut off valve on the (VAS 5190) until the fuel tank is empty.

CAUTION!
Do not run the fuel pump dry.

More than 3/4 Full

CAUTION!
Secure the fuel extracting device (VAS 5190 ) ground strap to a bare area on the chassis.

- Remove the cone piece - 2 - from the shaft piece - 1 - of the (VAS 5190).





- Using insulating tape, apply a mark - arrow - on the hose at length of 1,180 mm - a - from the end of the suction hose.

- Remove the fuel filler cap from the fuel filler tube.





- Install the shaft piece - 1 - of the (VAS 5190 ) in the fuel tank filler tube.

- Slide the suction hose into the fuel tank until the mark - arrow - applied earlier aligns with the shaft piece.

• A ball valve - 2 - that must not be damaged by the suction hose - 3 - is located in the fuel tank - 1 - at the lower end of the filler tube. Therefore, slide in the suction hose only up to the mark - arrow - applied earlier.





- Drain the fuel tank as much as possible via the fuel filler tube.

- Carefully pull out the suction hose.

• When no more fuel can be extracted, the tank is emptied only enough for the flange to be opened without danger. The tank may be removed while containing the remaining fuel.

• Draining the fuel tank completely, refer to => [ Less than 3/4 Full ].

Less than 3/4 Full

- Remove the rear seat bench.

- Remove the cover - 1 - with the fuel pump control module (J538) - 2 - from the fuel delivery unit.





CAUTION!
The fuel system is under pressure!

• Wear protective goggles and protective clothing to prevent injuries and contact with skin.

• Before disconnecting the connection, place a cloth around the connection point. Then release pressure by carefully disconnecting the connection.

- Disconnect the connector - 1 - and fuel lines - 2 and 3 - from the fuel delivery unit.





• Press the buttons together on the line connections to do so.

- Remove the locking ring using (T10202).





- Lift the fuel delivery unit up.

- Install the (VAS 5190) suction hose as far as possible into the fuel tank and extract the fuel.

If the fuel tank needs only to be drained, reinstall the fuel delivery unit. Refer to => [ Fuel Delivery Unit ] Fuel System Components.