Fuel Tank, Draining

Fuel Tank, Draining

Special tools, testers and auxiliary items required

• Fuel extracting device (VAS 5190)

• Wrench (T10202)

• Assembly tool (T10118)

Procedure

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

- Observe the rules for cleanliness. Refer to --> [ Clean Working Conditions ] Clean Working Conditions.

- Open the fuel tank door.

- Insert the suction hose - arrow - from the fuel extracting device (VAS 5190) about 170 to 180 cm into the fuel filler neck 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:

- Fold rear seat bench forward. On vehicles from 12.06, rear seat bench must be removed.

- Cut open carpet on the right side from point - A - to point - B - in the precut area - arrow -.





- Remove nuts - 1 - from the cover. If necessary, unbolt backrest support - 2 -or support mounting.





CAUTION!
Fuel supply lines are under pressure! Wear protective goggles and protective gloves to avoid damage and contact with skin. Before removing hose connection, wrap a cloth around the connection. Then release pressure by carefully separating the connection.

- Hold a cloth on the connections for the fuel supply line and auxiliary heater and pull off hose couplings.

• Release connection by pressing button on hose coupling.

- Pull off connectors for fuel pump and fuel gauge sender.

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





- Carefully pry out sender flange and raise it slightly.

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

- For work on the left side of the fuel tank, proceed as described before, only backrest support does not have to be removed. Only remove bolts - 1 - and then press backrest support up so all cover bolts - 2 - can be removed.





- When breather line is pulled off, hose coupling button often cannot be pressed in. In that case, use assembly tool (T10118) - arrow -.





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 replace sensor flange sealing ring.

- Insert sender flange with locating tab in direction of travel - arrow -.





- Tighten left and right locking rings using wrench (T10202) to 110 Nm.