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)

Procedure

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

- Open the fuel tank flap and remove the fuel cap.

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

- Insert the suction hose - arrow - from 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 sensor 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 the fuel tank sensors, proceed as follows:

Vehicles through 24 November 2006:

Vehicles from 27 November 2006.

- Fold the rear seat bench forward.

- Cut open the carpet from point - A - to point - B - in the precut area - arrows -.






Right Side of Vehicle:

- Remove the cover nuts - 1 -. Remove the backrest bearing - 2 - or bracket if necessary.






Left Side of Vehicle:

- Remove the bolts - 1 -.

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






Vehicles from 27 November 2006:

- Remove the rear seat bench.

Continuation for all Vehicles:

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






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

• Press in securing ring to disengage the fuel lines.

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






- Carefully pry out the sensor flange and raise it slightly.

- Insert the suction hose from 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 the fuel lines, it is possible that the securing rings on the hose connections cannot be pressed in. To do this, use the assembly tool (T10118).

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

If the fuel tank only needed to be drained, reinstall the sensor flange.

- First, check that sensor flange seals are properly seated.

• If the seals are swollen with fuel, always replace.

- Insert the sensor flange with the tab - arrow - in the direction of travel.






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

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






• Make sure the fuel hoses are secure.