All Wheel Drive
Fuel Tank, Draining
Special tools, testers and auxiliary items required
• Fuel Extracting Device (VAS 5190)
- Read the safety precautions before starting. Refer to => [ Safety Precautions ] Fuel Supply.
- Pay attention to the rules of cleanliness. Refer to => [ Clean Working Conditions ] Fuel Supply.
=> [ with the Fuel Delivery Sensor Installed ]
=> [ when the Tank is More Than 3/4 Full ]
=> [ when the Tank is Less Than 3/4 Full ]
with the Fuel Delivery Sensor Installed
Special tools, testers and auxiliary items required
• Adapter for Fuel Extraction (VAS 5190/3)
• Test Instrument Adapter/DSO (5-pin) (VAS 5565)
• Remote Control (V.A.G 1348/3A)
• The fuel supply line is under pressure. Always wear protective eye wear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Wrap a cloth around the connection before removing a fuel hose. Remove the hose connection carefully to release the pressure.
• Connect the fuel extracting device (VAS 5190) ground strap from the vehicle ground strap.
- Disconnect the supply line (metal coupling) - arrow - and wipe up any leaking fuel with a cloth.
• Press the locking ring to release the fuel lines.
- 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 - 1 - and the fuel pump control module - 2 - from the fuel delivery unit.
- Disconnect the connector - A - from the flange on the fuel delivery unit.
- 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 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 valve 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
Connect the fuel extracting device (VAS 5190) ground strap to the vehicles ground strap.
- Using insulating tape, apply a mark - arrow -on the suction hose at a length of 990 mm - a - from the end of hose.
- Remove the cap from the fuel filler tube.
- Slide the suction hose into fuel tank until the mark applied earlier aligns with the fuel filler tube.
• The shaft piece - 1 - is not used!
• A flap is located in the fuel tank on the lower end of the filler tube. It must not be damaged by the suction hose. Therefore slide in the hose only up to the mark applied earlier.
- Drain the fuel tank as much as possible via the fuel filler tube.
- Carefully pull out the suction hose.
• When no more fuel can be extracted, the tank is drained only enough for the flange to be opened without danger. The tank may be removed while containing the remaining fuel.
• 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
Special tools, testers and auxiliary items required
• Wrench (T10202)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
- Remove the rear seat bench.
• To drain the fuel tank completely, the fuel at the fuel delivery flange and fuel level sensor 2 flange must be extracted.
Drain the fuel tank at the fuel delivery unit flange.
Drain the fuel tank at the fuel level sensor 2 flange.
Drain the Fuel Tank at the Fuel Delivery Unit Flange:
- Remove the cover - 1 - and the fuel pump control module - 2 - from the fuel delivery unit.
• The fuel supply line is under pressure. Always wear protective eye wear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Wrap a cloth around the connection before removing 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 5 pin connector - A - and disconnect the fuel line - B - from flange.
• Press the locking ring to unlock the fuel line.
- 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 extract the fuel.
- Drain the fuel tank at the fuel level sensor 2 flange.
Drain the Fuel Tank at the Fuel Level Sensor 2 Flange:
- Disconnect the connector - arrow - from the all wheel drive control module.
- Remove the grommet - 1 - from the cover and guide the all wheel drive control module wiring harness downward and out.
- Remove the cover - 1 - and disconnect the 3 pin connector - arrow - from the flange.
- Remove the lock ring using the wrench (T10202).
- Lift the 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 only needed to be drained, reinstall the flanges with covers.
Flanges and Covers, Installing:
Install in the reverse order of removal. When doing this note the following:
• Only coat the seal with fuel when installing the flange.
• Make sure the lines connections are securely fastened.
- Note the flange location - arrows -:
The mark on the flange must align with the mark on the fuel tank - arrows -.
• The marks on the fuel tank are difficult to see.
A Fuel delivery unit flange
B Fuel level sensor 2 flange
- Tighten the lock ring using the wrench (T10202). Tightening specification: 110 Nm.
- Note the location of the covers - arrows -:
The - arrows - on the covers must point in the direction of travel.
A Fuel delivery unit cover
B Fuel level sensor 2 cover