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 ] Fuel Supply.

=> [ with Fuel Delivery Unit Installed ]

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

=> [ with Fuel 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)


• The fuel supply line is under pressure. Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Wrap a cloth around the connection before removing a fuel hose. Remove the hose connection carefully to release the pressure.

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

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






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

- Connect the fuel extracting device (VAS 5190) with the fuel extracting adapter (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 connector - arrow -.






- 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 the battery positive (+).

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

- Remove the cap from the fuel filler tube.

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


Do not run the fuel pump dry.

with Fuel Tank More Than 3/4 Full


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 - 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.






• There is a ball joint in the fuel tank on the lower end of the filler tube that must not be damaged by the suction hose - 1 -. 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 sensor flange to be opened without danger.

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

with Fuel Tank 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.







The fuel supply line is under pressure. Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Wrap a cloth around the connection before removing a fuel hose. Remove the hose connection carefully to release the pressure.

- Disconnect the connector - arrow -.






- Remove the fuel lines - 1 and 2 - from the flange.






• Press in the securing rings to disengage the fuel lines.

- Remove the locking ring using the wrench (T10202) and raise the flange slightly.






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

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