Procedures

Fuel Tank, Draining

=> [ with the Fuel Delivery Unit Installed ]

=> [ with a Faulty Fuel Pump ]

Special tools, testers and auxiliary items required

• Torque Wrench (5-50 Nm) (V.A.G 1332)

• Fuel Extracting Device (VAS 5190)

• Wrench (T10202)

- Read the safety precautions before starting. Refer to => [ Safety Precautions ] Fuel Supply.

with the Fuel Delivery Unit Installed

Special tools, testers and auxiliary items required

• Fuel Extracting Adapter (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 eyewear 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 fuel supply line - arrow -. To do so, press in the securing ring.






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






- Remove the rear bench seat.

- 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 battery positive (+).

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

- Remove the fuel 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 dry.

with a Faulty Fuel Pump

• Vehicles with engine codes BGQ and CBUA have a bayonet connection. The MY 11 Jetta with engine code CBTA has a 90° connection. These vehicles require a special adapter.

• If the adapter is not available, the threaded part of the fuel siphoning unit 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 - of 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.

- Install the shaft piece - 1 - on the fuel extracting device (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 the fuel extracting device operating instructions.

• The duel 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.