Procedures

WM 200317 Draining and filling fuel

Tools





Technical values





Tools and materials





Special tool WE 1262 with accessories






Information

- Fuel can be removed directly through the fuel filler neck on older vehicles or vehicles from other manufacturers by removing the connecting piece.





Connecting piece





Overview of fuel transfer system





1. Prepare fuel transfer unit for draining fuel.
1.1. Connect the fuel hose -1- to the changeover tank.





Fuel transfer system

1.2. Connect the venting device (transparent hose) to the changeover tank.
1.3. Attach the pneumatic stop switch -3- to the tank and tighten the two knurled nuts.
1.4. Then connect the suction hose at the connection -1-.
1.5. Connect the venting device -2-.
2. Connect the earth cable.
2.1. The earth cable must be connected to the vehicle while working with the unit. Use an unpainted metal part (e.g. the catch bar) for this -arrow-.





Earth cable attached to vehicle

Preliminary work

1. Place protective covers on the vehicle.
2. Disconnect and remove the battery.
-> 270619 Removing and installing battery - section on "Removing" 27061900 Removing and installing battery.
3. Remove carrier plate for battery.





Carrier plate for battery

3.1. Unscrew four hexagon collar nuts (M8) -1- and remove lid.
3.2. Check seal and replace it if necessary.

Draining fuel

WARNING

Highly inflammable or explosive materials

- Danger of fire or explosion

-> Avoid contact with hot parts or sources of ignition.
-> Use suction to remove ignitable vapours.
-> Attach warning sign in a clearly visible position.

Information

Fuel can be drained using the following methods:

> At the installed fuel level sensor via the adapter.

> Directly from the tank with the fuel level sensor removed.

1. Drain the fuel.
1.1. Drain fuel, fuel level sensor installed:
1.2. Release and pull off fuel line.
Soak up emerging fuel with a cloth.
1.2.1. RoW version:





Flange for fuel level sensor, RoW

1.2.2. USA version:





Flange for fuel-level sensor - USA

1.3. Attach Porsche adapter to the adapter. Twist top and bottom part of adapter in opposite directions until it is tight.





Porsche adapter

1.4. Screw the connecting piece into the suction hose and tighten it hand-tight.





Connecting piece

1.5. Connect suction hose at the fuel level sensor.





Connecting piece to adapter

1.6. Drain the fuel.
1.6.1. Set changeover lever to "Drain".
1.6.2. Switch on the transfer unit and drain the required amount of fuel.
2. Drain fuel, fuel level sensor removed:
2.1. -> 201519 Removing and installing fuel level sensor - section on "Removing" Service and Repair.
2.2. Disconnect connecting piece from suction hose.





Connecting piece

2.3. Insert suction hose into tank in order to drain fuel.
2.4. Drain the fuel.
2.4.1. Set changeover lever to "Drain".
2.4.2. Switch on the transfer unit and drain the required amount of fuel.


Filling fuel

WARNING

Highly inflammable or explosive materials

- Danger of fire or explosion

-> Avoid contact with hot parts or sources of ignition.
-> Use suction to remove ignitable vapours.
-> Attach warning sign in a clearly visible position.

Preliminary work:
1. Variant with fuel level sensor removed:
1.1. Install fuel level sensor.
-> 201519 Removing and installing fuel level sensor - section on "Installing" Service and Repair
2. Variant with fuel level sensor installed:
2.1. Fit all connections (fuel line, vent line and electric plugs).
The plug-in couplings must lock with an audible click.
2.2. RoW version:





Flange for fuel level sensor, RoW

2.3. USA version:





Flange for fuel level sensor, USA

3. Fill in fuel.
Connect the filling device as described in the operating instructions.
3.1. Fit fuel nozzle and set to "Delivery".
3.2. Refuel the vehicle using the filler neck. The fuel nozzle will switch off automatically.

Subsequent work

1. Install carrier plate for battery. Tighten four collar nuts. => Tightening torque: 23 Nm (17 ftlb.)
2. Install the battery.
-> 270619 Removing and installing battery - section on "Installing" 27061900 Removing and installing battery
3. Carry out a function test and check the system for leaks.
4. Remove protective covers.