Fuel Tank, Draining With Fuel Pump Installed

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

Special tools and workshop equipment required

Trim Removal Wedge: 3409
Injection Rate Comparison Meter Kit - Remote Cable: VAG1348/3A
Vehicle Diagnostic Tester - Test Adapter - 5 Pin: VAS5565
Fuel Extractor VAS5190A: VAS5190
Fuel Extraction Unit: VAS5190A for E 85 - fuel.
Fuel Extraction Adapter: VAS5190
Connector Test Set: VAG1594D

NOTE:

If the : VAS5190 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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

Pay attention to 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 : VAS5190 .

-- Install the : VAS5190/2 from the : VAS5190/10 on the suction hose.

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

Fig 2: Identifying Supply Line (Metal Coupling)

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

CAUTION:

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.

-- Connect the : VAS5190A and : VAS5190/3 to the fuel supply line.

Fig 3: Identifying Fuel Extraction - Adapter

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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

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

Fig 4: Identifying Cover With Fuel Pump Control Module J538

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Unclip the sealing flange cover -1- at the tabs in direction of -arrows- using the : 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 : VAS5565 to the connector and to the fuel delivery unit.

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Connect the : VAG1348/3A to the : VAS5565 and battery positive (+).

NOTE:

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

There is a risk of destroying the fuel pump if it runs dry.

Never let the fuel pump run >>dry<<.

-- Open the fuel filler door.

Fig 8: Filler Cap

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

-- Clean the area around the fuel filler neck.

-- Press the : VAG1348/3A and the shut-off valve on the : VAS5190 until the fuel tank is empty.

WARNING:

Risk of the fuel tank exploding when starting the fuel pump.

Severe injuries and burns are possible.

After installing a new or completely empty fuel tank, immediately fill with at least 5 liters of fuel.