Volkswagen Workshop Service and Repair Manuals

Emptying fuel tank if it is more than 3/4 full   Caution Secure earth wire of fuel extractor -VAS 5190- to a bare metal part of the body.

–  Remove cotter -2- from shaft -1- of fuel extractor -VAS 5190-.

Vehicles for USA/Canada –  At distance -a- = 1500 mm from end, mark extraction hose with insulating tape -arrow-. –  Remove filler cap from fuel tank filler neck.

–  Place shaft piece -1- of fuel extractor -VAS 5190- on fuel tank filler neck and hold. –  Insert suction hose in fuel tank until marking -arrow- (previously made) is at shaft section -1- and extract fuel → Operating instructions for fuel extractorVAS 5190.   Note t  After approx. 120 cm a pressure point is noticeable. The non-return flap in the fuel tank must be pushed open. Pull the hose out slightly and push it in with a slight jerk. t  The fuel tank is emptied almost completely in this way. t  Proceed in same manner when pulling hose out. t  Emptying the fuel tank completely → Chapter.

All other vehicles –  At distance -a- = 1180 mm from end, mark extraction hose with insulating tape -arrow-.

–  Remove filler cap from fuel tank filler neck. –  Screw shaft end -1- of fuel extractor unit -VAS 5190- onto fuel filler neck. –  Push extraction hose into fuel tank until marking on hose -arrow- coincides with shaft end.   Note

A ball valve -2- is located at the bottom of the filler neck in the fuel tank -1-; it must not be damaged by the extraction hose -3-. Therefore push hose into filler neck only as far as marking -arrow-. –  Drain fuel tank as much as possible through fuel filler neck. –  Carefully pull out extraction hose.   Note t  When no more fuel is extracted, the tank is emptied just enough for the sender flange to be opened without danger. The tank may be removed while containing remaining fuel. t  Draining fuel tank completely → Chapter