Draining A Fuel Tank More Than 3/4 Full, TDI Vehicles

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Special tools and workshop equipment required

Fuel Extractor:VAS 5190A

Fig 1: Fuel Extraction Device VAS5190A
Courtesy of AUDI
Fuel Funnel:T40256 or Emergency Refueling Funnel

Fig 2: A7 Sportback: Funnel
Courtesy of AUDI

Procedure

-- Pay attention to the safety precautions. Refer to SAFETY PRECAUTIONS .

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

-- Open the fuel filler door.

-- Clean the area around the fuel filler neck.

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

Fig 3: Fuel Filler Cap

Courtesy of AUDI

NOTE:

The adapter -1- and cone piece -2- from the Fuel Extraction Device Fuel Extractor:VAS 5190A will not be used.

Fig 4: Fuel Extracting Unit VAS5190 Demension -a-

Courtesy of AUDI

Push the adapter -1- on the hose slightly reward.

-- Attach the insulating tape -arrow- to the hose at a distance -a- from the end of the suction hose.

Dimension -a- = 1100 mm

-- Insert the Fuel Funnel:T40256 all the way into the fuel filler neck.

Courtesy of AUDI

NOTE:

A flap -1- is located in the fuel tank on the lower end of the fuel filler neck -2-. It must not be damaged by the suction hose from the Fuel Extraction Device Fuel Extractor:VAS 5190A . Only slide the hose in as far as the mark that was made earlier -arrow-.

Courtesy of AUDI

-- Slide the suction hose from the Fuel Extraction Device Fuel Extractor:VAS 5190A far enough into the fuel tank until the marking applied earlier -arrow- is on the edge of the fuel filler tube with the funnel -3-.

-- Empty the fuel tank through the fuel filler tube.

-- Carefully remove the suction hose.

NOTE:

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/FUEL LEVEL SENSOR, REMOVING AND INSTALLING, TDI VEHICLES .

Fig 5: Identifying Fuel Extraction Unit

Courtesy of AUDI

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

-- Slide the suction hose from the Fuel Extraction Unit Fuel Extractor:VAS 5190A into the fuel tank.

-- Extract the fuel from both fuel tank chambers through the opening using the Fuel Extractor:VAS 5190A .

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 .