Procedures

Fuel Tank, Draining

--> [ Engine Code BTK ]

--> [ Engine Codes BGP, BGQ, CBTA and CBUA ]

Special tools, testers and auxiliary items required

• Wrench (T10202)

• Fuel extracting device (VAS 5190)

• Torque wrench 40-200 Nm (VAG 1332)

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

Engine Code BTK

CAUTION!
Secure the (VAS 5190) ground wire to a bare area on the chassis.

Draining when More Than 3/4 Full

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





- Using insulating tape, apply a mark - arrow - on the hose at a length - a - = 1180 mm from the end of the suction hose.

- Remove the fuel filler cap.





- Install the shaft piece - 1 - for the (VAS 5190) into the fuel tank filler tube.

- Slide the suction hose as far into the fuel tank until the mark applied earlier - arrow - rests on 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 the hose in only up to the marking - arrow - applied earlier.





- Drain the fuel tank as much as possible.

- Carefully pull out the suction hose.

• When the fuel is no longer extracted, the fuel tank is emptied just enough to remove the fuel delivery unit safely.

• If fuel tank must be drained completely, proceed as follows:

Draining when Less Than 3/4 Full

- Switch off the ignition, switch off all electrical components and remove the ignition key.

- Remove the rear seat bench.

- Unclip the cover - 1 - for the fuel delivery unit. Arrow - 2 - points in direction of vehicle travel.





CAUTION!
Fuel supply line is under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before loosening the fuel lines, place a cloth around the connection point. Then release pressure by carefully disconnecting the connection.

- Disconnect the 5 pin electrical connector - 1 -, black supply line - 2 - and blue return line - 3 -.





• Press in the securing ring to disengage the lines.

- Remove the locking ring using the (T10202).





- Pull out the 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, install the fuel delivery unit. Refer to --> [ Fuel Delivery Unit ] Service and Repair.

Engine Codes BGP, BGQ, CBTA and CBUA

• Vehicles with engine codes BGQ and CBUA have a bayonet connection and require a corresponding adapter.

• If the adapter is not available, the threaded part of the fuel siphoning unit must be held in place.

CAUTION!
Secure the (VAS 5190) ground wire to a bare area on the chassis.

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





- Using insulating tape, apply a mark - arrow - on the hose at a length - a - = 1500 mm from the end of the suction hose.

- Remove the fuel filler cap.

- Install the shaft piece - 1 - for the (VAS 5190) into the fuel tank filler tube.





- Insert the suction hose into the fuel tank until the mark made earlier - arrow - is aligned with the shaft piece and extract the fuel. Refer to --> operating instructions for fuel extracting device (VAS 5190).

• A pressure point can be sensed after approximately 120 cm. The check valve in the fuel tank must be pushed open. Pull out hose slightly and slide it in using a light jerk.

• Fuel tank is drained almost completely.

• When pulling out hose, perform the same procedure.