Procedures

Fuel Tank, Draining

Special tools, testers and auxiliary items required

• Torque Wrench (40-200 Nm) (V.A.G 1332)

• Fuel Extracting Device (VAS 5190)

• Wrench (T10202)

=> [ with the Fuel Delivery Unit Installed ]

Engine Codes CBTA and CBUA => [ when the Tank is More Than 3/4 Full ]

Engine Code CCTA and CBFA => [ when the Tank is More Than 3/4 Full ]

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

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 which screws on.

- Follow all safety precautions. Refer to => [ Safety Precautions ] Safety Precautions.

- Follow the guidelines for cleanliness. Refer to => [ Clean Working Conditions ] Clean Working Conditions.

- Remove the tip - 1 - from the suction hose suction hose.

- Connect the adapter for fuel extraction (VAS 5190/3) from the adapter set for fuel extraction (VAS 5190/10) to the suction hose.

The fuel lines are under pressure.

Danger of personal injury to eyes and skin.

Wear protective goggles and protective clothing in order to avoid injury and contact with the skin. Wrap a cloth around the connection before removing a fuel hose. Open the connection carefully and release the pressure.

- Disconnect the fuel supply line - 1 - and wipe up any fuel with a cloth. Disconnecting the coupling, refer to => [ Coupling, Disconnecting ] Coupling, Disconnecting.

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

- Remove the rear seat bench.

- Remove the cover from the fuel delivery unit.

- Disconnect the connector - arrow -.

- Install 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 the positive (+) battery terminal.

• 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

• If the adapter for fuel extraction (VAS 5190/3) is not available, the threaded part of the fuel extracting device must be held in place.

• The fuel tank has a check valve installed. Be careful not to damage this check valve while extracting fuel.

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

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

- Apply insulating tape - arrow - to the suction hose 900 mm - a - from the end of the hose.

- Remove the cap from the fuel filler tube.

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

- Insert the suction hose into the fuel tank up to the tape mark - arrow - on the shaft piece and siphon out the fuel. Refer to the operating instructions for the fuel extracting device.

• Do not use force to pull the suction hose out it if gets stuck on the check valve.

• In this case, remove the fuel delivery unit and manually hold the check valve open. When doing this, make sure your arm does not come in contact with the fuel.

when the Tank is More Than 3/4 Full

• If the adapter for fuel extraction (VAS 5190/3) is not available, the threaded part of the fuel extracting device must be held in place.

• The fuel tank has a check valve installed. Be careful not to damage this check valve while extracting fuel.

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

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

- Push the suction hose into the fuel tank until it reaches the tape mark - arrow - on the suction hose made previously and extract the fuel. Refer to the operating instructions that come with the fuel extracting device.

• The fuel tank is drained almost completely.

• Do not use force to pull the suction hose out it if gets stuck on the check valve.

• In this case, remove the fuel delivery unit and manually hold the check valve open. When doing this, make sure your arm does not come in contact with the fuel.

when the Tank is Less Than 3/4 Full

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

- Remove the rear seat bench.

- Remove the cover - 1 - from the fuel delivery unit. The arrow - 2 - points in the direction of travel.

- Disconnect the connector - arrow - from the fuel delivery unit.

- Disconnect the fuel line from the fuel delivery unit flange. Disconnecting the coupling, refer to => [ Coupling, Disconnecting ] Coupling, Disconnecting.

- Remove the lock ring using the wrench (T10202).

- Lift the flange.

- Insert the suction hose from the fuel extracting device (VAS 5190) as far as possible into the fuel tank and siphon out the fuel.

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

Tightening Specifications