Procedures
Fuel Tank, Draining
Special tools, testers and auxiliary items required
• Fuel extracting device (VAS 5190)
• Wrench (T10202)
• Torque wrench (40 to 200 Nm) (V.A.G 1332)
- Read safety precautions before beginning work => [ Safety Precautions ] Table of Contents.
Drain the fuel tank with the fuel pump installed => [ Fuel Tank, Draining with Fuel Pump Intact ]
Draining fuel tank when more than 3/ 4 full => [ Fuel Tank, Draining when More Than 3/4 Full ]
Draining fuel tank when less than 3/ 4 full => [ Fuel Tank, Draining when Less Than 3/4 Full ]
Fuel Tank, Draining with Fuel Pump Intact
Special tools, testers and auxiliary items required
• Fuel extracting adapter (VAS 5190 /3)
• Test instrument adapter/DSO (5-pin) (VAS 5565)
• Remote control connection (V.A.G 1348/3A)
CAUTION!
• Fuel supply line is under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.
• Connect the Fuel Extractor (VAS 5190) ground strap from the vehicle ground strap.
- Disconnect supply line - arrow - and catch escaping fuel using a rag.
• Press in securing ring to disengage the fuel lines.
- Connect the Fuel Extractor Unit (VAS 5190) with the Adapter (VAS 5190 /3) to the fuel supply line.
- Remove seat bench => Body Interior 72 Rear seats; removing and installing seat bench.
- Remove cover - 1 - with Fuel Pump (FP) Control Module (J538) - 2 - from fuel delivery unit.
- Disconnect harness connector - A - from flange of fuel delivery unit.
- Place the test instrument adapter/DSO (5-pin) (VAS 5565) on the connector and on the fuel delivery unit.
- Connect the remote control (V.A.G 1348/3A) to the adapter (VAS 5565) and battery plus (+).
• This work step allows the fuel pump to run when the engine is not running.
- Remove fuel filler cap from fuel filler tube.
- Operate the remote control (V.A.G 1348/3A) and the shut-off valve on the fuel extracting device (VAS 5190) until the fuel tank is empty.
Fuel Tank, Draining when More Than 3/4 Full
CAUTION!
Secure the fuel extracting device (VAS 5190) ground wire to a bare area of the chassis.
- Using insulating tape, apply a mark on hose - arrow - at length - a - = 990 mm from end of suction hose.
- Remove fuel filler cap from fuel filler tube.
- Slide suction hose as far into fuel tank until the mark applied earlier meets fuel filler tube.
• Shaft piece - 1 - is not used!
• A flap that must not be damaged by the suction hose is located in fuel tank at lower end of fuel filler tube. Therefore slide in hose only up to the marking applied earlier.
- Empty fuel tank as much as possible via fuel filler tube.
- Carefully pull out the suction hose.
• When no more fuel is being siphoned, fuel tank is emptied just enough to open sensor flange safely. The tank may be removed while containing the remaining fuel.
• How to drain fuel tank completely => [ Fuel Tank, Draining when Less Than 3/4 Full ].
Fuel Tank, Draining when Less Than 3/4 Full
- Remove rear seat bench => Body Interior 72 Seats, rear.
- Remove cover - 1 - with Fuel Pump (FP) Control Module (J538) - 2 - from fuel delivery unit.
CAUTION!
Fuel supply line is under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.
- Disconnect the 5-pin connector - A - and disconnect the fuel line - B - from flange.
• Press in securing ring to disengage the fuel line.
• On vehicles with auxiliary heater, harness connector and fuel line of Metering Pump (V54) must also be disconnected.
- Open locking ring using wrench (T10202).
- Lift sensor flange.
- Insert the fuel extracting device (VAS 5190) suction hose as far as possible into the fuel tank and extract the fuel.
If fuel tank needs only to be drained, install sensor flange again => [ Fuel Delivery Unit, Removing and Installing ] Fuel Delivery Unit, Removing and Installing.