Procedures

Fuel Tank Draining

Special tools, testers and auxiliary items required

• Fuel extracting device (VAS 5190)

• Wrench (T10202)

• Torque wrench (40 to 200 Nm) (VAG 1332)

Procedure

- Read safety precautions before beginning work. Refer to --> [ Safety Precautions ] Service Precautions.

- Open fuel tank door and remove fuel tank cap.

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

- Insert the suction hose - arrow - on the fuel extracting device (VAS 5190) approximately 170 to 180 cm into the fuel filler tube and extract the fuel.





• When no more fuel can be extracted, the tank is emptied only enough for the sender flange to be opened without danger. The tank may be removed while containing the remaining fuel. If work must be performed on the fuel pumps or fuel tank sensors, proceed as follows:

Vehicles through Calender Week (CW) 47/06

Vehicles from CW 48/06.

- Fold rear seat bench forward

- Cut open carpet from point - A - to point - B - in pre cut area - arrows -.





Right Side of Vehicle

- Remove cover nuts - 1 -. If necessary, backrest support - 2 - or bracket may have to be removed.





Left Side of Vehicle

- Remove bolts - 1 -.

- Then remove nuts - 2 -. Bracket will have to be pressed upward slightly to remove one of the nuts.





Vehicles from CW 48/06

- Remove rear seat bench.

Continuation for All

- Disconnect harness connector for fuel pump and tank sensor - 4 -.





- Disconnect return line - 1 -, supply line - 2 - as well as supply line for auxiliary heater - 3 - from right sensor flange.

• Press in securing ring to disengage the fuel lines.

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





- Carefully pry out sender flange and raise it slightly.

- Insert the suction hose on the fuel extracting device (VAS 5190) as far as possible into the right or left side of the fuel tank and extract the fuel.

- For work on left side of fuel tank, proceed as described above.

- When disconnecting fuel lines, it is possible that the securing rings on the hose connections cannot be pressed in. To do this, insert assembly tool (T10118).

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

If fuel tank only needed to be emptied, install sensor flange again.

- First check that sender flange seals are properly seated.

• If seals are swollen with fuel, always replace.

- Insert sender flange with marking in direction of travel - arrow -.





- Tighten left and right locking rings using wrench (T10202) to 145 Nm.

• Do not interchange supply and return lines (return line -blue- - 1 -, supply line -black- - 2 -).





• Ensure fuel hoses are seated securely.