Fuel Tank, Draining, Fuel Delivery Unit Faulty

Special tools and workshop equipment required

Fuel Extractor: VAS5190A
Fuel Extraction - Adapter 2: VAS5190/2

Procedure

-- Observe the safety instructions. Refer to SAFETY PRECAUTIONS .

-- Follow the guidelines for clean working conditions. Refer to GUIDELINES FOR CLEAN WORKING CONDITIONS .

-- Attach a suitable adapter from the : VAS5190/10 onto the suction hose -1- from the : VAS5190A .

Fig 1: Fuel Extracting Device

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-- Move the front seats all the way forward into the highest position.

-- Switch off the ignition.

-- Open the fuel filler door.

Fig 2: The Fuel Filler Cap

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-- Remove the fuel filler neck cap -arrow-.

-- Disconnect the ground cable from the battery terminal. Refer to BATTERY, DISCONNECTING AND CONNECTING .

WARNING:

Risk of explosion due to electrostatic charge.

Secure the ground wire of the : VAS5190A to a bare area on the body.

Q7:

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WARNING:

The fuel system is under pressure.

Risk of injury from fuel spraying out.

Wear protective eyewear.
Wear safety gloves.
Reduce the pressure: place clean cloths around the connection point and carefully open the connection point.

-- Free up the fuel hose from the brackets -1 and 3- and disconnect the connector coupling -2-. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

Q8:

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WARNING:

The fuel system is under pressure.

Risk of injury from fuel spraying out.

Wear protective eyewear.
Wear safety gloves.
Reduce the pressure: place clean cloths around the connection point and carefully open the connection point.

-- Free up the fuel hose -1- at the bracket -2- and disconnect the connection coupling -3-. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

Continuation for All Vehicles:

-- Attach the suction hose with : VAS5190/2 to the supply line in the engine compartment.

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CAUTION:

Risk of fuel entering vehicle interior.

For only partly filled fuel tanks, the fuel in the right container half can also be up to the height of the sealing flange. Approximately 15 liters of fuel must therefore be extracted using the : VAS5190A before opening the sealing flange.

-- Extract approximately 15 liters (4 gallons) of fuel through the supply line using the : VAS5190A .

Q7:

-- Remove the right front and rear sill panels. Refer to SILL PANEL, REMOVING AND INSTALLING .

-- Remove the bench seat / right and center single seats. Refer to BENCH SEAT/SINGLE SEAT, REMOVING AND INSTALLING .

-- Remove the right luggage compartment floor support. Refer to OVERVIEW - LUGGAGE COMPARTMENT FLOOR .

-- Remove the rear cover -1- for both seat rails on the front passenger seat. To do so, carefully release the tabs -3, 4 and 5- on the seat rail -2- using a screwdriver.

Fig 3: Unclipping Retaining Tabs On Cover From Seat Rail And Removing Cover

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NOTE:

The front passenger seat does not need to be removed.

-- Remove the carpet under the seat rail.

-- Remove the covers and connector station for the bench seat / single seats in the carpet.

-- Fold the carpet near the sealing flange cover to the side.

Q8:

-- Remove the seat frame mount. Refer to SEAT FRAME MOUNT, REMOVING AND INSTALLING .

Continuation for All Vehicles:

-- Remove the bolts -1, 2 and 3- and remove the sealing flange cover.

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-- Release the catches -arrows- using a screwdriver and remove the Fuel Pump Control Module -J538- -1- from the bracket.

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-- Release and disconnect the connector -2- for the Fuel Pump Control Module -J538-.

-- Release the catch -2- with a screwdriver and turn the bracket -1- for the Fuel Pump Control Module -J538- counter-clockwise in direction of -arrow-.

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-- Disengage the bracket at the locking ring and remove.

-- Release and disconnect the connectors -1 and 2- from the sealing flange.

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-- Vehicles with parking heater: disconnect the fuel line -1- to the parking heater metering pump at the sealing flange. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

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-- Disconnect the fuel line -2- from the sealing flange. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

Fig 4: Identifying Fuel Sending Unit Wrench

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WARNING:

Danger due to escaping fuel.

To prevent large quantities of fuel from leaking when removing the fuel delivery unit, the fuel tank may only be a maximum of ¹ /₄ full.

-- Remove the locking ring using the : T10202 .

-- Pull the sealing flange -1- slightly out of the fuel tank opening and remove the seal -2-.

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-- With the sealing flange lifted, slide the suction hose from the : VAS5190A through the opening into the fuel tank.

Fig 5: Identifying Fuel Extraction Unit

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-- Extract fuel from both fuel tank chambers with the : VAS5190A .

Assembling

Assemble in the reverse order of removal. Note the following:

Q7:

-- Install the support for the luggage compartment floor. Refer to OVERVIEW - LUGGAGE COMPARTMENT FLOOR .

-- Install the bench seat / single seats. Refer to BENCH SEAT/SINGLE SEAT, REMOVING AND INSTALLING .

-- Install the sill panels. Refer to SILL PANEL, REMOVING AND INSTALLING .

Q8:

-- Install the seat frame mount. Refer to SEAT FRAME MOUNT, REMOVING AND INSTALLING .