Draining fuel tank (four-wheel drive, USA vehicles): Audi TT Mk2 (BPY, BUB, BWA, CBRA, …)

🧭 Before you start

Fits: Audi TT Mk2 (8J, 2006–2014)

• Special tools named: VAS 5190

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• Risk of explosion caused by electrostatic discharge.Secure earth wire of fuel extractor VAS 5190 to a bare metal part on the body. — Detach tapered adapter (2) from shaft end (1) of fuel extractor VAS 5190.
• Use insulating tape to mark the extraction hose (arrow) at a distance of (a) = 1,370 mm from the end of the hose.
• When removing, make sure you do not bend float arm of fuel gauge sender 2 G169.

🔧 Engine codes this applies to

📐 56 workshop diagrams for BPY

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. Release the tank flap.
2. ⚠ To prevent irreparable damage to the electronic components when disconnecting the battery:Observe notes on procedure for disconnecting the battery. — Disconnect battery Electrical system27Battery; Disconnecting and connecting battery.
3. ⚠ Risk of explosion caused by electrostatic discharge.Secure earth wire of fuel extractor VAS 5190 to a bare metal part on the body. — Detach tapered adapter (2) from shaft end (1) of fuel extractor VAS 5190.
4. Use insulating tape to mark the extraction hose (arrow) at a distance of (a) = 1,370 mm from the end of the hose.
5. Remove filler cap from fuel filler neck.

6. Screw shaft end of fuel extractorVAS 5190 onto fuel filler neck.
7. Push extraction hose into fuel tank until marking on hose (arrow) coincides with shaft end. [Note: The procedure when using a fuel extractor without a shaft end is fundamentally the same.In this case, make a mark (arrow) on the extraction hose at distance (a) = 1,305 mm from the end of the hose using insulating tape. The extraction hose has been properly inserted when the affixed mark is level with the edge of the filler neck.If hose is difficult to insert, apply a thin coat of engine oil. DO NOT use silicone-based lubricant.]
8. Drain fuel tank as much as possible through fuel filler neck.
9. Carefully remove extraction hose.
10. Remove rear seat bench General body repairs, interior72Rear seats; Removing and installing seat bench/individual seats.
11. Remove back panel side trim (left-side) General body repairs, interior70Passenger compartment trim panels; Overview of fitting locations - passenger compartment trim panels.
12. Unclip the retaining tabs (arrows) for the flange cover (left-side).
13. Unplug electrical connector (1) at flange.
14. Disengage electrical connector (2) and move it clear to the side.
15. Unscrew locking ring using wrench T10202.
16. Carefully pull fuel gauge sender 2G169(item 1) with suction-jet pump just slightly out of aperture in fuel tank. [Note: When removing, make sure you do not bend float arm of fuel gauge sender 2 G169.]
17. Extract fuel from left fuel tank chamber through fuel tank opening using fuel extractorVAS 5190.
18. Push hose into right-hand chamber of fuel tank and extract remaining fuel.
19. Re-install fuel gauge sender 2G169; observe notes on procedure for connecting battery.

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