Fuel tank, draining

WARNING: This page does not describe the selected car, but rather 15 other vehicles, including the 2008 Audi S4, 2008 Audi RS 4, 2008 Audi A4, 2007 Audi S4, and 2007 Audi RS 4. However, it is still accessible from the selected car via links, so may be relevant.

Special tools, testers and auxiliary items required

Fig 1: Identifying Wrench T10202

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Wrench T10202

Fig 2: Identifying Fuel Extraction Unit VAS 5190

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fuel siphoning unit VAS 5190

Work procedure

Observe safety precautions → Safety precautions when working on fuel supply system .

Observe rules for cleanliness → Rules for cleanliness .

CAUTION:

Observe procedures for disconnecting battery →
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET
.

All except Audi RS4:

Fig 3: Pushing Cover Over Battery Toward Right And Removing It Upward

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Push cover over battery toward right - arrow 1 - and remove it upward - arrow 2 -.

Fig 4: Locating Battery Ground Strap

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With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.

Audi RS4:

Raise luggage compartment floor covering and secure.

Fig 5: Disconnecting Battery Ground (GND) Strap

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With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.

All:

CAUTION: Secure Ground (GND) wire of fuel extraction unit VAS 5190 to a bare area of the chassis.

Fig 6: Pulling Cone Piece From Shaft Piece Of Fuel Siphoning Device VAS 5190

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Pull cone piece - 2 - from shaft end - 1 - of fuel extraction unit VAS 5190.
Using insulating tape, apply a mark - arrow - on hose at length - a - = 1,865 mm from end of suction hose.
Remove fuel filler cap from fuel filler tube.

Fig 7: Installing Fuel Siphoning Device VAS 5190 Onto Fuel Filler Tube Of Fuel Tank

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Screw shaft end - 1 - of fuel extraction unit VAS 5190 on to fuel filler tube of fuel tank.
Push suction hose as far into fuel tank until mark applied earlier - arrow - is positioned on shaft end.

NOTE:

If using a siphoning device without shaft end, proceed basically in the same manner.

Fig 8: Sliding Suction Hose As Far Into Fuel Tank Until Mark Applied Earlier Meets Fuel Filler Tube

Courtesy of VOLKSWAGEN UNITED STATES, INC.

In this case, apply a mark - arrow - using insulating tape on hose at length - a - = 1,800 mm from end of suction hose. The suction hose is inserted correctly when the marking applied earlier stands opposite the lip of fuel filler tube.
If the hose can only be inserted with difficulty, coat it thinly with engine oil. Never use lubricants containing silicon.

Drain fuel tank through fuel filler tube as much as possible.
Carefully pull out suction hose.
Remove rear seat bench →
- 72 - SEAT - FRAMES
- 72 - SEAT - FRAMES for BODY INTERIOR - CABRIOLET
.

Fig 9: Removing Cover Bolts For Locking Flange

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Unbolt cover for right locking flange - arrows -.
Disconnect electrical harness connector - arrow - at right locking flange.

Audi RS4:

Fig 10: Removing Electrical Wires With Connector From Locking Flange Opening

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Free up electrical connector - arrow - for Fuel Pump (FP) Control Module J538 and disconnect.

All:

Fig 11: Disconnecting Electrical Harness Connector At Right Locking Flange

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical harness connector - arrow - at right locking flange.

Fig 12: Identifying Fuel Return Line And Fuel Supply Line

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Mark fuel return line - 1 - and fuel supply line - 2 -.

CAUTION: The fuel system is under pressure! Before opening system, place rags around the connection area. Then release pressure by carefully loosening the connection.

Pull both lines from locking flange, by pressing release buttons.

Fig 13: Removing/Installing Locking Ring With Wrench T10202

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Remove locking ring using wrench T10202.
Pull locking flange and sealing ring from opening of fuel tank.

Fig 14: Inserting Suction Hose Through Right Opening Of Fuel Tank Into Left Fuel Tank Chamber

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert suction hose, a dimension of - x - = 800 mm in length, through right opening of fuel tank into left fuel tank chamber.
Drain left fuel tank chamber.
Install right locking flange again Installing , observing notes for connecting battery →
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET
.