Emptying fuel tank, four-wheel drive, engine codes BJB, BLS, BSU — AUDI

🧭 Before you start

Fits: VW Caddy III (2K, 2004–2015); platform code 2C0

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• The fuel pump is being activated when engine is not running.
• At a distance of (a) = 1700 mm from end of extraction hose, use insulating tape to mark (arrow) the hose of the fuel extractorVAS 5190.
• The non-return valve in the fuel tank must not be damaged by the extraction hose. You must therefore push the hose into the filler neck only as far as the marking.
• When no more fuel is extracted, the tank is emptied just sufficiently to allow the connecting hose (1) to be pulled off. Proceed as follows to extract more fuel.
• In order to extract the remaining fuel from the 2nd chamber, the fuel tank has to be lowered and fuel gauge sender 2G169 lifted up .

🔧 Engine codes this applies to

📋 Procedure

1. ⚠ Fuel supply line is pressurised. Wear eye protection and protective clothing to avoid injury and skin contact. Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.Connect fuel extractorVAS 5190 earth wire to vehicle earth. — Pull off supply line (2) and catch escaping fuel with a cloth.
2. Connect fuel extractorVAS 5190 with adapter for fuel extractorVAS 5190 /3 to fuel supply line.
3. With ignition switched off, connect vehicle diagnosis, testing and information systemVAS 5051B or vehicle diagnosis and service information systemVAS 5052.
4. Switch ignition on.
5. Remove cap from fuel filler neck.

6. Perform function "“Draining fuel system”" in "“Guided functions”".
7. Operate shut-off tap on fuel extractorVAS 5190, until the fuel tank is emptied. [Note: The fuel pump is being activated when engine is not running.] [Note: Fuel tank must be drained completely to remove it.] [Note: Observe safety precautions .Observe rules for cleanliness .]
8. Remove cone piece (2) from shaft (1) of fuel extractorVAS 5190.
9. At a distance of (a) = 1700 mm from end of extraction hose, use insulating tape to mark (arrow) the hose of the fuel extractorVAS 5190.
10. Open tank flap.
11. Remove cap from fuel filler neck.
12. Push extraction hose into fuel tank until marking on hose coincides with filler neck. [Note: The non-return valve in the fuel tank must not be damaged by the extraction hose. You must therefore push the hose into the filler neck only as far as the marking.]
13. Drain fuel tank as far as possible.
14. Pull extraction hose out carefully. [Note: When no more fuel is extracted, the tank is emptied just sufficiently to allow the connecting hose (1) to be pulled off. Proceed as follows to extract more fuel.]
15. ⚠ Fuel tank must not be more than 3/4 full.Fuel supply line is pressurised. Wear eye protection and protective clothing to avoid injury and skin contact. Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection. — Loosen screw-type clip (2) and pull connecting hose (1) off fuel tank.
16. ⚠ The fuel tank union contains the non-return valve flap, which must not be damaged by the suction hose. — Carefully insert suction hose of fuel extractorVAS 5190 as far as possible into fuel tank. Extract fuel. [Note: In order to extract the remaining fuel from the 2nd chamber, the fuel tank has to be lowered and fuel gauge sender 2G169 lifted up .]

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