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) , or equivalent

• Vehicle Diagnostic Tester

• Adapter Set for Fuel Extraction (VAS 5190/3)

=> [ with the Fuel Delivery Unit Installed ]

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

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

with the Fuel Delivery Unit Installed

• If the fuel extracting device (VAS 5190) has a suction hose with a mounted tip - 1 -, then replace this with one that has a tip which screws on.






- Remove the tip - 1 - from the fuel extracting device (VAS 5190) suction hose.

- 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 remains 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.

- Disconnect the supply line - arrow - and wipe up any fuel that has leaked out. Disconnecting the coupling, refer to => [ Coupling, Disconnecting ] Coupling, Disconnecting.






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






- Disconnect the connector - A - from the auxiliary fuel pump/fuel pump 2 (in-line electric fuel pump).






- Connect the vehicle diagnostic tester.

- Turn the ignition on.

- Remove the cap from the fuel filler tube.

- Operate the vehicle diagnostic tester and perform the "Empty fuel system" guided function.

• The fuel pumps are now activated. The vehicle diagnostic tester shows the progress of the draining.

- Open the shut off valve on the fuel extracting device (VAS 5190) until the fuel tank is empty.

• The coupling must audibly engage when locking.

• Note the color code when installing the coupling. Refer to => [ Coupling Allocation: ] Coupling, Disconnecting!

• Pull on the coupling to make sure it is secure.

• Disconnecting the coupling. Refer to => [ Coupling, Disconnecting ] Coupling, Disconnecting.

when 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 - at a length of 1,180 mm - a - from the end of the suction hose.

- Remove the cap from the fuel filler tube.






- 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 - arrow - applied earlier 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 suction hose only up to the mark - arrow - applied earlier.






- Drain the fuel tank as much as possible.

- 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.

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

when Tank is Less Than 3/4 Full

- Remove the rear seat bench.

- Remove the cover for the fuel delivery unit.


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.

- First, pull on the connector - arrow - without pressing the retainer to make sure it is connected securely. If the connector was not connected correctly, it could cause a fault.






- Disconnect the connector - arrow -.

- Disconnect the fuel lines from the flange. Disconnecting the couplings. Refer to => [ Coupling, Disconnecting ] Coupling, Disconnecting.

- 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 the fuel only needed to drained, then reinstall the flange. Refer to => [ Fuel Delivery Unit ] Fuel Delivery Unit.

• The coupling must audibly engage when locking.

• Note the color code when installing the coupling. Refer to => [ Coupling Allocation: ] Coupling, Disconnecting!

• Pull on the coupling to make sure it is secure.

• Disconnecting the coupling. Refer to => [ Coupling, Disconnecting ] Coupling, Disconnecting.