Procedures

Fuel Tank Draining

=> [ Tank More than 3/4 Full ]

=> [ Tank Less than 3/4 Full ]

Special tools, testers and auxiliary items required

• Torque wrench (V.A.G 1332)

• Fuel extracting device (VAS 5190)

• Wrench (T10202)

- Read safety precautions before beginning work => [ Fuel Supply System Safety Precautions ] Fuel Supply System Safety Precautions.

- Observe the rules for cleanliness => [ Clean Working Conditions ] Fuel Supply System.

Tank More than 3/4 Full

CAUTION!
Secure the fuel extracting device (VAS 5190) ground wire to a bare area of 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 hose at length - a - = 1,180 mm from end of suction hose.

- Remove fuel filler cap from fuel filler tube.





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

- Slide suction hose as far into fuel tank until the mark applied earlier - arrow - stands on shaft piece.

• A ball valve - 2 - that must not be damaged by the suction hose - 3 - is located in fuel tank - 1 - at lower end of filler tube. Therefore slide in hose only up to the marking - arrow - applied earlier.





- Drain fuel tank as much as possible.

- Carefully pull out the suction hose.

• When fuel is no longer extracted, fuel tank is emptied just enough to open the fuel delivery unit safely.

• Fuel tank must be drained completely => [ Tank Less than 3/4 Full ].

Tank Less than 3/4 Full

- Turn the ignition and all electrical consumers off and remove the ignition key.

- Remove seat bench

- Unclip cover - 1 - from fuel delivery unit. Arrow - 2 - points in direction of travel.





CAUTION!
• The fuel or fuel lines in fuel system can become very hot (danger of scalding)!

• In addition, the fuel system is under pressure! Before opening the system, place rags around the connection area and release pressure by carefully loosening the connection!

• Wear protective goggles and protective gloves when working on the fuel system!

- Disconnect the connector - 1 -, the supply line - 2 - and the return line - 3 - from the fuel delivery unit.





• Press in securing ring to disengage the lines.

• On vehicles equipped with an auxiliary heater, the metering pump (V54) electrical connector must also be disconnected and the fuel pipe must be removed.

- Open locking ring using wrench (T10202).





- Pull out fuel delivery unit slightly.

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

If the fuel tank needs only to be drained, install fuel delivery unit again.