Fuel Tank, Draining With Fuel Pump Installed

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Special Tools And Workshop Equipment Required

Trim Removal Wedge 3409
Injection Rate Comparison Meter Kit - Remote Cable VAG 1348/3A
Vehicle Diagnostic Tester - Test Adapter - 5 Pin VAS 5565
Fuel Extraction Unit VAS 5190
Fuel Extractor Unit VAS 5190A (without illustration) for E 85 - fuel type.
Fuel Extraction Adapter VAS 5190
Connector Test Set VAG 1594D

NOTE:

If the Fuel Extraction Unit VAS 5190 has a suction hose with a mounted tip, then replace that with one that has a tip that screws on.

Fig 1: Fuel Extracting Device

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NOTE:

Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

Follow the guidelines for clean working conditions. Refer to PARKING/AUXILIARY HEATER AND FUEL SYSTEM CLEAN WORKING CONDITIONS .

-- Remove the tip -1- from the fuel extraction hose for the Fuel Extraction Unit VAS 5190.

-- Install the Fuel Extraction - Adapter 2 VAS 5190/2 from the Fuel Extraction - Adapter Set VAS 5190/10 on the suction hose.

-- Remove the fuel supply line -1- and wipe up any fuel with a cloth. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, SEPARATING .

Fig 2: Identifying Supply Line (Metal Coupling)

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-- Connect the Fuel Extraction Unit VAS 5190 and Fuel Extraction - Adapter 3 VAS 5190/3 to the fuel supply line.

Fig 3: Identifying Fuel Extraction - Adapter

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-- Attach the Fuel Extraction Unit VAS 5190 Ground (GND) cable to an ungrounded area on the body.

-- Remove the bench seat. Refer to REMOVAL AND INSTALLATION .

-- If equipped, remove the Fuel Pump Control Module -J538- -2- from the cover -1-.

Fig 4: Identifying Cover With Fuel Pump Control Module J538

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-- Unclip the locking flange cover -1- at the tabs -arrows- using the Trim Removal Wedge 3409.

Fig 5: Identifying Right Cover

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-- Disconnect the connector -arrow-.

Fig 6: Fuel Pump Control Module Connector

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-- Attach the Vehicle Diagnostic Tester - Test Adapter - 5 Pin VAS 5565 to the connector and to the fuel delivery unit.

Fig 7: Connecting Remote Control VAG 1348/3A To Test Instrument Adapter/DSO (5-Pin) VAS 5565 And To Battery Plus (+)

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-- Connect the Injection Rate Comparison Meter Kit - Remote Cable VAG 1348/3A to the Vehicle Diagnostic Tester - Test Adapter - 5 Pin VAS 5565 and battery positive (+).

NOTE:

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

-- Open the fuel filler door.

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

Fig 8: Identifying Filler Cap

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-- Clean the area around the fuel filler tube.

-- Press the Injection Rate Comparison Meter Kit - Remote Cable VAG 1348/3A and the shut-off valve on the Fuel Extractor Unit VAS 5190 until the fuel tank is empty.