Fuel Tank, Draining

Fuel Tank, Draining

=> [ with the Fuel Delivery Unit Installed ]

=> [ when the Tank is More Than 3/4 Full ]

=> [ when the Tank is Less Than 3/4 Full ]

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 the Fuel Delivery Unit Installed

Special tools, testers and auxiliary items required

• Adapter for Fuel Extraction (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 wire to the vehicles ground wire.

- Disconnect the fuel supply line - arrow - and wipe up the leaking fuel with a clean cloth.






• Press the locking ring to release the fuel line.

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






- Remove the rear seat bench.

- Remove the cover from the fuel delivery unit.






- Disconnect the connector - arrow -.






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






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

• 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 lever on the fuel extracting device (VAS 5190) until the fuel tank is empty.

when the Tank is 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).






- Apply a mark - arrow - on the suction hose 1,180 mm - a - from the end of the suction hose.

- Remove the cap from the fuel filler tube.

- Insert the shaft piece - 1 - for the fuel extracting device (VAS 5190) into the fuel tank filler tube.






- Slide the suction hose into the fuel tank far enough so the mark - arrow - applied earlier is aligned 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 through the filler tube.

- Remove the suction hose carefully.

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

• To drain the fuel tank completely, refer to => [ when the Tank is Less Than 3/4 Full ].

when the Tank is Less Than 3/4 Full

• To drain the fuel tank completely, the fuel must be extracted through the fuel delivery unit flange and fuel level sensor 2 flange.

- Remove the rear seat bench.

- Remove the cover for the fuel delivery unit.






- Disconnect the connector - arrow -.







The fuel system 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 fuel lines - 1 and 2 - from the flange.






• Press the locking ring to release the fuel lines.

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






- 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.

Draining the Fuel Tank at the Fuel Level Sensor 2 Flange

- Remove the cover.






- Disconnect the connectors - 1 and 2 -.






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






- 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.

Reinstall the flanges if only the fuel tank needed to be drained. Refer to => [ Installed Position of the Fuel Delivery Unit Flange and the Fuel Level Sensor 2 Flange ] Fuel Tank and Attachments Overview.