Fuel Delivery and Air Induction: Service and Repair

Draining the fuel tank AWD and 2WD/ORVR

Draining the fuel tank

Special tools:
981 2270 PUMP TROLLEY 981 2270 Pump Trolley
981 2273 PUMP 981 2273 Pump
981 2282 Tank 981 2282 Tank
998 5972 JACK 998 5972 Jack
999 5484 Adapter 999 5484 Adapter

Alternative
There are two different methods for draining the fuel tank depending on whether the fuel pump works.

Hint: If the tank is more than half full, it can take a long time to drain. Alternative 2 could then be preferable even if the fuel pump works.

- Alternative 1: if the fuel pump works, see Draining the fuel tank via the fuel rail
- Alternative 2: if the fuel pump does not works, see Draining a lowered fuel tank (AWD only)

Draining the fuel tank via the fuel rail


Hint: Use this method if the fuel pump works.

Preparation
Connect an exhaust evacuator and start the engine.

Removing the cover





Remove:
- the cover of the throttle control reel
- the protective cap over the fuel rail valve.

Draining the fuel tank




Connect adapter 999 5484 Adapter 999 5484 Adapter to fuel draining unit 981 2270 PUMP TROLLEY 981 2270 Pump Trolley , 981 2273 PUMP 981 2273 Pump , and 981 2282 Tank 981 2282 Tank.
The adapter should not be connected to the pump of the draining unit but should lead down into the container.
Connect the adapter to the valve of the fuel rail in the locked position (valve closed).
Start draining.
Open the adapter (valve open).
The fuel pump in the fuel tank will now pump the fuel down into the container.

Fitting the cover
Refit the equipment in reverse order.




Do not forget to remount the protection and covers over the valves and return the fuel to the fuel tank once repairs are complete.

Draining a lowered fuel tank (AWD only)


Hint: Use this method if the fuel pump does not work.
If the tank is more than half full, it can take a long time to drain. This method could then be preferable even if the fuel pump works.

Preparation
If the fuel pump does not work, the fuel system must be drained in accordance with Draining fuel injection system Draining Fuel Injection System and the entire rear axle including the fuel tank lowered.

Draining the fuel tank
Tip the fuel tank slightly upwards so that the openings for the pump and ejector have the highest position.
Remove all fuel lines and fittings.

Caution! Refit the retaining nuts, otherwise the tank sleeve coupling will swell and the nut will be difficult to fit with risk of shearing.

Suck the fuel from the RH and LH tank halves with an open hose connected to the fuel draining unit.

Caution! Make sure there is proper ventilation and keep in mind the risk of fire!

Fitting
Refit the equipment in reverse order.
Do not forget to return the fuel to the tank once repairs are completed.