Procedures

Fuel Tank, Draining

=> [ with a Faulty Fuel Pump ]

=> [ with the Fuel Delivery Unit Installed ]

Special tools, testers and auxiliary items required

• Fuel Extracting Device (VAS 5190) , or equivalent

• Wrench (T10202)

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

with a Faulty Fuel Pump

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

- Follow the guidelines for cleanliness. Refer to => [ Clean Working Conditions ] Clean Working Conditions.

- Open the fuel tank door.

- Remove the incorrect fuel protection. Refer to => [ Incorrect Fuel Protection ] Service and Repair.

- Apply insulating tape - arrow - to the suction hose on the fuel extracting device at a length of 1800 mm (71 inches) - a - from the end of the hose.






• The suction hose is inserted correctly when the mark applied aligns with the lip of the fuel filler neck.

- Install the suction hose into the fuel filler tube and extract the fuel.

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

• If work must be performed on the fuel level sensor 3 or on the suction jet pumps.

• If work must be performed on the fuel pump or on the fuel level sensor , proceed as follows:

- Remove the right rear seat or seat back.

- Fold the right carpet to the side.






- Remove the flange cover nuts - 1 through 4 - and flange cover.

If the battery is connected, make sure that the fuel pump is not activated when the driver's door is opened. Fuel may leak out when the system is open.

- Disconnect the fuel return line - 1 -.






- Disconnect the fuel supply line - 2 - and the fuel line for the auxiliary heater - 4 -. Disconnecting the couplings. Refer to => [ Coupling, Disconnecting ] Coupling, Disconnecting.

If the battery is connected, make sure that the fuel pump is not activated when the driver's door is opened. Fuel may leak out when the system is open.

- Disconnect the fuel level sensor connector - 3 - and the fuel pump connector - 5 -.

- Remove the lock ring from the flange using the wrench (T10202).






- Carefully lift the flange.

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

- To siphon out fuel and to work on the left side of the fuel tank, perform the following:

- Remove the left rear seat or seat back.

- Fold the carpet to the side.






- Remove the flange cover nuts - 1 through 4 - and flange cover.

- Disconnect the connector - arrow - from the flange.






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






- Carefully lift the flange.

- Disconnect the fuel level sensor 3 connector - arrow - from the flange, if necessary.






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

For additional work on components inside of the fuel tank, the flanges may remain removed.

If the fuel tank only needed to be drained, reinstall the flanges again.

- Replace the seals for the flanges if they are damaged.

- Install the flanges in the direction of travel - arrow -.






The tab on the flange - 2 - must be between the tabs - 1 and 3 - on the fuel tank.

- Tighten the lock ring to 145 Nm using the wrench (T10202).






• Do not interchange the right side supply and return lines. The return line - 1 - is blue and the supply line - 2 - is black.






• Make sure the coupling connections are secure.

with the Fuel Delivery Unit Installed

If the battery is connected, make sure that the fuel pump is not activated when the driver's door is opened. Fuel may leak out when the system is open.

The fuel supply line is under pressure. Wear protective goggles and protective clothing in order to avoid injury and contact with the skin. Wrap a cloth around the connection before removing a fuel hose. Then release pressure by carefully loosening the union nut.

- Disconnect the fuel supply line - 1 - from the fuel filter.






- Connect the hose (VAS 6551/2) using the connection fitting (VAS 6551/5-1) to the fuel supply line - 1 -.

- Insert the open end of the hose (VAS 6551/2) into the fuel extracting device (VAS 5190).

- Connect the vehicle diagnostic tester and perform the guided function "activate fuel pump".

• The fuel pump is now activated.

- Repeat this procedure as necessary until the fuel tank is completely empty.