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 starting. Refer to => [ Safety Precautions ] Safety Precautions.

=> [ with Fuel Delivery Unit Installed ]

=> [ with Tank More Than 3/4 Full ]

=> [ with Tank 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)


Fuel system is under pressure!

• Always wear protective eye-wear and protective clothing to prevent injuries and fuel from coming in contact with your skin.

• Before loosening line connections, place a cloth around the connection point. Then release pressure by carefully pulling off the line.

• For safety reasons, interrupt the current supply to the fuel pump, refer to => [ Safety Precautions ] Safety Precautions before opening the fuel system because the fuel pump is activated by the drivers door contact switch.

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

- Disconnect the supply line (metal coupling) - arrow - and wipe up any leaking fuel with a cloth.






• Press the locking ring to release the fuel line.

- Connect the fuel extracting device (VAS 5190) and the fuel extracting adapter (VAS 5190/3) to the fuel supply line.






- Remove the rear bench seat.

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






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






- Install the test instrument adapter/DSO (5-pin) (VAS 5565) between the connectors on the cover and the fuel delivery unit.






- Connect the remote control (V.A.G 1348/3A) to the test instrument adapter/DSO (5-pin) (VAS 5565) and to battery positive (+).

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

- Remove the fuel cap from the fuel filler tube.

- Operate the remote control (V.A.G 1348/3A) and the shutoff lever on the fuel extracting device (VAS 5190) until the fuel tank is empty.


Do not run the fuel pump dry.

with Tank More Than 3/4 Full


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

- Remove the cone piece - 2 - from the shaft piece - 1 - on the fuel extracting device (VAS 5190).






- Using insulating tape, apply a mark - arrow - on the suction hose at length of 820 mm - a - from the end of the hose.

- Slide the suction hose into the fuel tank until the mark applied earlier - arrow - meets the fuel filler tube.

• 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 hose only up to the mark - arrow - applied earlier.






- Drain the fuel tank as much as possible.

- 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.

• If fuel tank must be drained completely, refer to => [ with Tank Less Than 3/4 Full ].

with Tank Less Than 3/4 Full

- Remove the rear bench seat.

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







Fuel system is under pressure!

• Always wear protective eye-wear and protective clothing to prevent injuries and fuel from coming in contact with your skin.

• Before loosening line connections, place a cloth around the connection point. Then release pressure by carefully pulling off the line.

- Disconnect the connector - 1 - and remove the fuel lines - 2 and 3 - from the flange.






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

- Remove the locking ring using the wrench (T10202).






- Lift the sensor flange.

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

If the tank only needed to drained, then reinstall the flange. Refer to => [ Fuel Delivery Unit ] Fuel System Components.