Procedures

Fuel Tank, Draining

Special tools, testers and auxiliary items required

• Wrench (T10202)

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

• Fuel Extracting Device (VAS 5190)


• Observe the safety precautions when working on the fuel supply system. Refer to => [ Safety Precautions ] Fuel Supply.

• Observe the rules for cleanliness. Refer to => [ Clean Working Conditions ] Fuel Supply.

Always follow these instructions before and during work.

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

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

When the Tank is More Than 3/4 Full


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).






- Using insulating tape, apply a mark - arrow - on the hose at length of 1,180 mm - a - from the end of the suction hose.

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






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

- Slide the suction hose into the fuel tank until the mark applied earlier - arrow - aligns with 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 in the hose only up to the mark - arrow - 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 fuel delivery unit to be opened without danger.

• If the fuel tank must be drained completely, refer to => [ When the Tank is Less Than 3/4 Full ].

When the Tank is Less Than 3/4 Full

- Remove the rear bench seat.






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


• The fuel supply line is under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin.

• Before loosening the connection, place a cloth around the connection point. Then, release pressure by carefully disconnecting the connection.

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






• Press in the securing ring to disengage the fuel lines.

- Seal the lines so that the fuel system is not contaminated by dirt, etc.

- Remove the lock ring using wrench (T10202).






- Lift the fuel delivery unit flange.

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

If the fuel tank only needed to be emptied, reinstall the fuel delivery unit. Refer to => [ Fuel Delivery Unit ] Fuel Delivery Unit.