Procedures

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 starting. Refer to => [ Safety Precautions ] Safety Precautions.

=> [ With Fuel Delivery Unit Installed ]

=> [ More Than 3/4 Full ]

=> [ Less Than 3/4 Full ]

With Fuel Delivery Unit Installed

Special tools, testers and auxiliary items required

• Fuel Extracting Device (VAS 5190)

• Fuel Extracting Adapter (VAS 5190/3)

• Connector Test Set (V.A.G 1594 C)

• Wiring diagram


• The fuel supply line is under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before disconnecting the connection, wrap a cloth around the connection. Then release pressure by carefully disconnecting the connection.

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

- Disconnect the supply line (metal coupling) - arrow - and wipe up any draining fuel with a cloth.






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

- Connect the (VAS 5190) with the (VAS 5190 /3) to the fuel supply line.






- Remove the cap from the fuel filler tube.

- Remove the rear bench seat.

- Remove the cover from the fuel delivery unit.






- First pull on the connector - arrow - without pressing the retainer to make sure it connected securely. If the connector was not connected correctly, it could cause a fault.






- Disconnect the connector.

- Check the contacts on the connector and the fuel delivery unit for damage.

- Install the (VAS 5565) between the connectors on the fuel delivery unit and cover.






- Connect the (V.A.G 1348/3A) to the (VAS 5565) and to the battery positive terminal.

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


Do not run the fuel pump dry.

More Than 3/4 Full


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

- Remove the cone piece - 2 - from the shaft piece - 1 - on the (VAS 5190).






- Using insulating tape, apply a mark - arrow - on hose at length of 820 mm - a - from the end of suction hose.

- Slide the suction hose - 1 - into the fuel tank until the mark - arrow - applied earlier 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 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 flange to be opened without danger.

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

Less Than 3/4 Full

- Remove the rear bench seat.

- Remove the cover from the fuel delivery unit.







The fuel system is under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before disconnecting the connection, wrap a cloth around the connection. Then release pressure by carefully disconnecting the connection.

- Remove the connector - 1 - and fuel lines - 2 and 3 - from the flange.






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

- Remove the locking ring using (T10202).






- Lift the flange.

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

If the fuel tank needs only to be drained, reinstall the flange. Refer to => [ Fuel Delivery Unit ] Service and Repair.