Volkswagen Workshop Service and Repair Manuals

Emptying fuel tank when fuel pump is intact (CAYA, CAYB, CAYC) Special tools and workshop equipment required

t  Removal wedge -3409-

t  Fuel extractor -VAS 5190-

t  Adapter for fuel extraction -VAS 5190 /2-   Note

If the fuel extraction unit -VAS 5190- is still fitted with the extraction hose with a fixed tip, the extraction hose must be replaced with the version with a screwed tip. –  Unscrew tip -1- from extraction hose of fuel extraction unit -VAS 5190-. –  Screw fuel extraction adapter -VAS 5190 /2- from fuel extraction adapter set -VAS 5190 /10- onto extraction hose.   WARNING Danger of burning from very hot fuel. t  In extreme cases the fuel lines and the fuel can reach a temperature of 100 °C. Allow the fuel to cool down before disconnecting the lines - danger of scalding. t  Wear protective gloves. t  Wear eye protection. Risk of injury due to highly pressurised fuel. To release pressure in fuel system, place clean cloth around connection and carefully undo connection. »Carry out the following work sequence« Removing –  Fold front right seat forwards as far as possible. Uncover fuel delivery unit. –  Fold rear seat bench forwards or remove → General body repairs, interior; Rep. gr.72.

–  Unclip cover -1- for flange at retaining tabs -arrows-, using removal wedge -3409-.

–  First check that the connector -arrow- is fitted securely by pulling the connector without pressing the catch. The connector can cause a fault if it has not been fitted correctly. –  Disconnect fuel supply line -1- at the sealing flange. Disconnect push-on connector → Chapter.   Note Disregard -item 2-.

–  Connect extraction hose with fuel extraction adapter -VAS 5190 /2- to supply line connection of sealing flange. –  Drain fuel tank with fuel extraction unit -VAS 5190- through the supply line connection of sealing flange. –  Connect vehicle diagnostic tester and perform guided function „Fuel pump activation“.   Note The fuel pump is now activated. The vehicle diagnosis tester shows the progress of the drainage. –  Open shut-off tap on fuel extractor -VAS 5190- until fuel tank is emptied.