Fuel Tank, Draining

Fuel Tank, Draining

Special tools, testers and auxiliary items required

• Fuel Extracting Device (VAS 5190)

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

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

=> [ With Fuel Delivery Unit Installed ]

=> [ More Than 3/4 Full ]

=> [ Less Than 3/4 Full ]

With 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)

CAUTION!
• The fuel supply line is under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before disconnecting the connection, wrap a cloth around the connection. Carefully disconnect the connection to release the pressure.

• Connect the (VAS 5190) ground strap to the vehicle ground strap.

- Disconnect the supply line (metal coupling) - arrow - and collect any leaking fuel with a cloth.





• Press in the securing ring to disengage the fuel lines.

- Connect the (VAS 5190) with the (VAS 5190 /3) to the fuel supply line.





- Remove the rear seat bench.

- Remove the cover - 1 - with fuel pump control module (J538) - 2 - from the fuel delivery unit.





- Disconnect the connector - A - from the flange on the fuel delivery unit.





- Install the (VAS 5565) between the connectors on the fuel delivery unit and cover.





- Connect the (V.A.G 1348/3A) to the (VAS 5565) and the battery positive (+) terminal.

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

- Remove the cap from the fuel filler tube.

- Operate the (V.A.G 1348/3A) and the shut off valve on the (VAS 5190) until the fuel tank is empty.

CAUTION!
Do not run the fuel pump dry.

More Than 3/4 Full

CAUTION!
Connect the (VAS 5190) ground strap to the vehicle ground strap.

- Using insulating tape, apply a mark - arrow - on the hose at length of 990 mm - a - from the end of the suction hose.





- Remove the cap from the fuel filler tube.

- Slide the suction hose as far into the fuel tank until the mark applied earlier meets fuel filler tube.

• The shaft piece - 1 - 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 extracting hose. Therefore slide in hose only up to the mark applied earlier.

- Empty the fuel tank as much as possible via the fuel filler tube.

- Carefully pull out the suction hose.

• When no more fuel can be extracted, the tank is emptied only enough for the flange to be opened without danger. The tank may be removed while containing the remaining fuel.

• Draining the fuel tank completely. Refer to => [ Less Than 3/4 Full ].

Less Than 3/4 Full

Special tools, testers and auxiliary items required

• Wrench (T10202)

• Torque Wrench (40 to 200 Nm) (V.A.G 1332)

- Remove the rear seat bench.

• To empty the fuel tank completely, the fuel at the fuel delivery flange and fuel level sensor 2 (G169) flange must be extracted.

Empty the fuel tank at the fuel delivery unit flange.

Empty the fuel tank at the fuel level sensor 2 flange.

Emptying the Fuel Tank at the Fuel Delivery Unit Flange

- Remove the cover - 1 - with fuel pump control module (J538) - 2 - from the fuel delivery unit.





CAUTION!
• The fuel supply line is under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before disconnecting the connection, wrap a cloth around the connection. Carefully disconnect the connection to release the pressure.

• Connect the (VAS 5190) ground strap to the vehicle ground strap.

- Disconnect the 5 pin connector - A - and disconnect the fuel line - B - from the flange.





• Press in the securing ring to disengage the fuel line.

- Remove the locking ring using (T10202).





- Lift the flange.

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

- Empty the fuel tank at the fuel level sensor 2 flange.

Emptying the Fuel Tank at the Fuel Level Sensor 2 Flange

- Disconnect the connector from the all wheel drive control module (J492) - arrow -.





- Remove the grommet - 1 - from the cover and guide the all wheel drive control module wiring harness downward and out.

- Remove the cover - 1 - and disconnect the 3 pin connector - arrow - from the flange.





- Remove the locking ring using (T10202).





- Lift the flange.

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

If the fuel tank should only be emptied, reinstall the flanges and covers.

Flange and Cover, Installing

Install in reverse order of removal. When doing this note the following:

• Only lubricate the seal with fuel when installing the flange.

• Make sure the line connections are securely fastened.

- Note the flange location - arrows -:





The mark on the flange must align with the mark on the fuel tank - arrows -.

• The mark on the fuel tank is difficult to see.

A Fuel delivery unit flange
B Fuel level sensor 2 flange

- Tighten the locking ring using (T10202). Tightening specification: 110 Nm.

- Note the location of the covers - arrows -:





- Arrows - on the covers must point in direction of travel.

A Fuel delivery unit cover
B Fuel level sensor 2 cover