Fuel Tank, Draining, Vehicles With TDI Engine, Fuel Delivery Unit (Fuel Pump) Faulty

Special tools and workshop equipment required 

• Fuel Extractor: VAS5190A 
  Fig 1: Fuel Extraction Device VAS5190A

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• Fuel Extraction - Adapter 3: VAS 5190/3 
  Fig 2: Identifying Fuel Extraction Adapter

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• Hand drill
• 3.5 mm diameter drill bit

Procedure 

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-- Attach the adapter : VAS 5190/3  -2- to the suction hose -1- on the fuel extractor: VAS5190A  .

-- Open the fuel filler door.

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

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

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

-- Fold the insulation mat over the sealing flange cover to the side. Separate it at the perforations if necessary to do so.

-- Remove the bolts -arrows- and the sealing flange cover -1-.

Version without parking/auxiliary heater: 

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-- Create a 3.5 mm diameter hole in an empty, closed connection -arrow- for the parking/auxiliary heater fuel line.

-- To prevent fuel from leaking out, connect the adapter : VAS 5190/3  to the drilled connection immediately.

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Versions with parking/auxiliary heater: 

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-- Disconnect the fuel line -1- to the metering pump. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

-- To prevent fuel from leaking, connect the adapter : VAS 5190/3  to the fuel connection for the parking/auxiliary heater immediately.

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Continuation for All Vehicles: 

-- Extract the fuel using the Fuel Extractor Unit: VAS5190A  .

TIP:

When no more fuel can be extracted, the tank is emptied only enough for the sealing flange to be opened without danger.

-- Open the sealing flange. Refer to FUEL DELIVERY UNIT, REMOVING AND INSTALLING, TDI VEHICLES .

-- Pull the sealing flange out of the opening in the fuel tank just a little.

-- Slide the suction hose from the Fuel Extraction Unit : VAS5190A  into the fuel tank.

-- Extract the fuel from both fuel tank chambers through the opening using the Fuel Extractor: VAS5190A  .

The remaining steps to be performed will depend on the issue.

-- Replace the fuel delivery unit. Refer to FUEL DELIVERY UNIT/FUEL LEVEL SENSOR, REMOVING AND INSTALLING .

-- Remove the Fuel Level Sensor -G-. Refer to Fuel Level Sensor -G-, REMOVING AND INSTALLING .

-- Remove the fuel tank. Refer to FUEL TANK, REMOVING AND INSTALLING .