Procedures

Fuel Tank, Draining

=> [ with the Fuel Delivery Unit Installed ]

=> [ when the Tank is More Than 3/4 Full ]

=> [ when the Tank is Less Than 3/4 Full ]

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 the safety precautions before starting. Refer to => [ Safety Precautions ] Safety Precautions.

with the Fuel Delivery Unit Installed

Special tools, testers and auxiliary items required

• Adapter Set for Fuel Extraction (VAS 5190/10)

• Test Instrument Adapter/DSO (5-pin) (VAS 5565)

• Remote Control (V.A.G 1348/3A)

• If the fuel extracting device (VAS 5190) has a suction hose with a mounted tip - 1 -, then replace this with one that has a tip - 2 - which screws on.







• The fuel supply line is under pressure. Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Wrap a cloth around the connection before disconnecting a fuel hose. Remove the hose connection carefully to release the pressure.

• Connect the fuel extracting device (VAS 5190) ground strap to the vehicles ground strap.

- Disconnect the fuel supply line (metal coupling) - 1 - and catch any leaking fuel with a clean cloth. Disconnecting the couplings, refer to => [ Coupling, Disconnecting ] Coupling, Disconnecting.






- Connect the fuel extracting device (VAS 5190) and the adapter for fuel extraction (VAS 5190/3) to the fuel supply line.






- Remove the rear seat bench.

- Fold up the carpet to the right of the fuel delivery unit.

- Remove the cover - 1 -.






- Disconnect the connector - arrow -.






- Connect the test instrument adapter/DSO (5-pin) (VAS 5565) between the connectors on the fuel delivery unit and cover.






- Connect the remote control (V.A.G 1348/3A) to the test instrument adapter/DSO (5-pin) (VAS 5565) and to battery positive (+).

• This step allows the fuel pump to run when the engine is not running.

- Remove the cap from the fuel filler tube.

- Operate the remote control (V.A.G 1348/3A) and the shut off lever on the fuel extracting device (VAS 5190) until the fuel tank is empty.


Do not run the fuel pump when it is dry.

when the Tank is More Than 3/4 Full


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

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






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

- Remove the fuel cap from the fuel filler tube.

- Insert the shaft piece - 1 - from the fuel extracting device (VAS 5190) into the fuel tank filler tube and hold it.






- Push the suction hose into the fuel tank until the mark on the suction hose - arrow - aligns with the shaft piece - 1 - and extract the fuel. Refer to the Operating Instructions for the 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 the hose slightly and slide it in using a light jerk.

• The fuel tank is drained almost completely.

• Remove the hose the same way.

• To drain the fuel tank completely, refer to => [ when the Tank is Less Than 3/4 Full ].

when the Tank is Less Than 3/4 Full

- Remove the rear seat bench.

- Remove the cover - 1 - and the fuel pump control module (J538) - 2 - from the fuel delivery unit.







The fuel supply line is under pressure. Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Wrap a cloth around the connection before disconnecting a fuel hose. Remove the hose connection carefully to release the pressure.

- Disconnect the connector - arrow -.






- Disconnect the fuel lines - 1 and 2 - from the flange. Disconnecting the couplings, refer to => [ Coupling, Disconnecting ] Coupling, Disconnecting.






- Remove the lock ring using the wrench (T10202) and raise the flange slightly.






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

If the fuel only needed to drained, then reinstall the sensor flange. Refer to => [ Fuel Delivery Unit/Fuel Level Sensor ] Service and Repair.