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Home >> Volkswagen >> 2006 >> GTI 1.8 E, Automatic >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 23 (2.0L - Fuel Supply - Engine Code(S): BPY (As Of 12.2010)) >> 20 Fuel Supply >> General Information >> Fuel Tank, Draining >> With The Fuel Delivery Unit Installed

With The Fuel Delivery Unit Installed

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required 

WARNING:

Fuel system is under pressure!

  • Always wear protective eye-wear and protective clothing to prevent injuries and fuel from coming in contact with your skin.
  • Before loosening line connections, place a cloth around the connection point. Then release pressure by carefully pulling off the line.
  • Connect the fuel extracting device VAS 5190 ground wire to the vehicles ground strap.

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

Fig 1: Disconnecting Supply Line And Catch Escaping Fuel Using Rag
GWWA20-10135Courtesy of VOLKSWAGEN UNITED STATES, INC.
NOTE:

Press the locking ring to release the fuel line.

-- Connect the fuel extracting device VAS 5190 and the fuel extracting adapter VAS 5190/3 to the fuel supply line.

Fig 2: Connecting Fuel Extracting Device VAS 5190 And Fuel Extracting Adapter VAS 5190/3 To Fuel Supply Line
GWWN20-10482Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Remove the rear bench seat. Refer to Removal and Installation .

-- Remove the cover -1- and the fuel pump control module -J538- -2- from the fuel delivery unit.

Fig 3: Identifying Cover With Fuel Pump Control Module J538
GWWN20-0603Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Disconnect the 5 pin connector -arrow- from the flange on the fuel delivery unit.

Fig 4: Identifying Fuel Delivery Unit Connector
GWWA20-1067Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Install the test instrument adapter/DSO (5-pin) VAS 5565 between the connectors on the cover and the fuel delivery unit.

Fig 5: Connecting Remote Control V.A.G 1348/3A To Test Instrument Adapter/DSO (5-Pin) VAS 5565 And To Battery Plus (+)
GWWN20-10422Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Connect the remote control V.A.G 1348/3A to the test instrument adapter/DSO (5-pin) VAS 5565 and to battery positive (+).

NOTE:

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

-- Remove the fuel cap from the fuel filler tube.

-- Operate the remote control V.A.G 1348/3A and the shutoff lever on the fuel extracting device VAS 5190 until the fuel tank is empty.

CAUTION:

Do not run the fuel pump dry.

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