Fuel Tank, Draining
Engine Code BPS (Plastic Fuel Tank)
Fuel Tank, Draining
Fuel delivery unit installed, refer to Fuel Delivery Unit Installed.
More than 3/4 full, refer to More Than 3/4 Full.
Less than 3/4 full, refer to Less Than 3/4 Full.
Special tools, testers and auxiliary items required
• Torque wrench (40-200 Nm) (VAG 1332)
• Fuel extracting device (VAS 5190)
• Wrench (T10202)
- 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
Fuel Delivery Unit Installed
Special tools, testers and auxiliary items required
• Fuel extracting adapter (VAS 5190/3)
• Remote control (VAG 1348/3A)
• Connector test set (VAG 1594C)
CAUTION!
Fuel system is under pressure!
• Wear protective goggles and protective clothing to prevent injuries and contact with skin.
• Before loosening the line connection, place a cloth around the connection point. Then release pressure by carefully loosening the line.
• Connect the (VAS 5190) ground strap to the vehicles ground cable.
- Disconnect the fuel supply line - 3 - and absorb any leaking fuel with a clean cloth.
• Press the securing ring to disengage the line.
- Connect the (VAS 5190) with the (VAS 5190/3) to the fuel supply line.
• The illustration shows a different vehicle.
- Remove the fuel filler cap from the fuel filler tube.
- Fold the rear seat bench forward.
- Remove the cover from the fuel delivery unit.
- Disconnect the 4 pin electrical connector from the fuel delivery unit.
- Connect the (VAG 1348/3A) with an adapter cable to terminal - 1 - of the fuel pump and to the battery positive (+).
- Connect terminals - 4 - of the harness connector and fuel pump using an adapter cable from (VAG 1594 C).
• This step allows the fuel pump to run when the engine is not running.
- Remove the fuel filler cap from fuel filler tube.
- Operate the (VAG 1348/3A) and the shut off valve on the (VAS 5190) until the fuel tank is empty.
More Than 3/4 Full
CAUTION!
Secure the (VAS 5190) ground wire to a bare area on the chassis.
- Remove the cone - 2 - from the shaft piece - 1 - of the (VAS 5190).
- Using insulating tape, apply a mark - arrow - on the hose at length - a - = 820 millimeters (mm) from the end of the suction hose.
- Remove the fuel filler cap from the fuel filler tube.
- Install the shaft piece - 1 - from the (VAS 5190) into the fuel tank filler tube.
- Slide the hose into the fuel tank until the mark applied earlier - arrow - aligns 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 hose only up to the mark - arrow - applied earlier.
- Drain the fuel tank as much as possible.
- Carefully pull out the suction hose.
• When fuel is no longer extracted, the fuel tank is emptied just enough to open the fuel delivery unit safely.
• If the fuel tank must be drained completely, refer to Less Than 3/4 Full.
Less Than 3/4 Full
- Fold the rear seat bench forward.
- Remove the cover from the fuel delivery unit.
CAUTION!
Fuel system is under pressure!
• Wear protective goggles and protective clothing to prevent injuries and contact with skin.
• Before loosening the connections, place a cloth around the connection point. Then release pressure by carefully loosening the connection.
- Disconnect the 4 pin electrical connector - 1 -, black supply line - 2 - and blue return line - 3 - from the fuel delivery unit. Press in the securing ring to disengage the lines.
- Remove the locking ring using (T10202).
- Pull out fuel delivery unit slightly.
- Insert the (VAS 5190) suction hose as far as possible into the fuel tank and extract the fuel.
If fuel tank needs only to be drained, reinstall the fuel delivery unit. Refer to => [ Fuel Delivery Unit ] Removal and Replacement.