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)
• Trim Removal Wedge (3409)
• Adapter Set for Fuel Extraction (VAS 5190/10)
=> [ With the Fuel Delivery Unit Installed ]
=> [ When the Tank is More Than 3/4 Full ]
=> [ When the Tank is Less Than 3/4 Full ]
Very hot fuel can burn your skin.
• In extreme cases the temperature of the fuel lines and/or the fuel can go up to 100 °C (212 °F). Let the fuel cool down before opening any line connections otherwise there is a danger of scalding.
• Wear protective gloves.
• Wear safety glasses.
There is a risk of injury because the fuel is under high pressure.
• To reduce pressure in fuel system, lay a clean cloth around the connector and carefully loosen connector.
With the Fuel Delivery Unit Installed
• If the fuel extracting device (VAS 5190) has a suction hose with a mounted tip - 1 -, then replace it with one that has a tip which screws on.
- Remove the tip - 1 - from the suction hose on the fuel extracting device (VAS 5190).
- 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 supply line is under pressure. 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. Remove the hose connection carefully to release the pressure.
- Follow all safety precautions. Refer to => [ Fuel Supply System Safety Precautions ] Fuel Supply System Safety Precautions.
- Follow the guidelines for cleanliness. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
- Disconnect the supply line - arrow - (black) and wipe up the leaking fuel with a cloth. Disconnecting the couplings, refer to => [ Coupling, Disconnecting ] Coupling, Disconnecting.
Secure the fuel extracting device (VAS 5190) ground wire to a bare area on the chassis.
- Connect the fuel extracting device (VAS 5190) and adapter for fuel extraction (VAS 5190/3) to the fuel supply line.
- Open the fuel filler tube door.
- Remove the locking cap - arrow - from the fuel filler tube.
- Clean the area around the fuel filler tube.
- Turn on the ignition.
- Perform the Guided Function "Empty Fuel System" in the vehicle diagnostic tester.
• The fuel pump is activated. The vehicle diagnostic tester shows the progress of the draining.
- Open the shut off lever on the fuel extracting device (VAS 5190) until the fuel tank is empty.
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.
- Follow all safety precautions. Refer to => [ Fuel Supply System Safety Precautions ] Fuel Supply System Safety Precautions.
- Follow the guidelines for cleanliness. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
- Remove the cone piece - 2 - from the shaft piece - 1 - on the fuel extracting device (VAS 5190).
- Attach insulating tape - arrow - to the hose at a distance of 1020 mm - a - from the end of the suction hose.
• The adapter - 2 - is not used!
• A flap is located in the fuel tank on the lower end of the filler neck. It must not be damaged by the suction hose. Therefore, slide the hose in only as far as the mark made earlier.
- Open the fuel filler tube door.
- Remove the locking cap - arrow - from the fuel filler tube.
- Clean the area around the fuel filler tube.
- Insert the shaft piece - 1 - from the fuel extracting device (VAS 5190) into the fuel tank filler tube.
- Slide the suction hose into the fuel tank until the mark made earlier - arrow - aligns with the shaft piece - 1 - on the fuel extracting device (VAS 5190).
- Drain the fuel tank as much as possible through the filler tube.
- Remove the suction hose carefully.
Do not use force to pull the suction hose it if gets stuck on the check valve.
• In this case, remove the fuel delivery unit and manually hold the check valve open. Refer to => [ Fuel Delivery Unit ] Fuel Delivery Unit.
• When no more fuel can be extracted, the tank is drained only enough for the sensor flanges to be opened without danger.
• 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
- Follow all safety precautions. Refer to => [ Fuel Supply System Safety Precautions ] Fuel Supply System Safety Precautions.
- Follow the guidelines for cleanliness. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
- Remove the rear seat bench.
- Remove the flange cover - 1 - using the trim removal wedge (3409) - arrows -.
- Unlock and disconnect the connector - arrow -.
The fuel supply line is under pressure. 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. Remove the hose connection carefully to release the pressure.
- Disconnect the fuel lines - 1 and 3 - from the flange. Disconnecting the couplings, refer to => [ Coupling, Disconnecting ] Coupling, Disconnecting.
- Remove the lock ring using the wrench (T10202) and lift the flange slightly.
- 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 the fuel tank only needed to be emptied, reinstall the sensor flange. Refer to => [ Fuel Delivery Unit ] Fuel Delivery Unit.
Tightening Specifications
