Draining fuel tank in event of faulty fuel pump, engine codes BTK, CCCA — VW

🧭 Before you start

Fits: VW Jetta VI (16, 2010–2018), VW Golf V / Jetta (1K, 2003–2009); platform code AJ5

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• Use insulating tape to mark the extraction hose (arrow) at a distance of (a) = 1180 mm from the end of the hose.
• 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).
• When no more fuel can be extracted, the tank is emptied just enough for fuel delivery unit to be removed without danger.If the fuel tank has to be drained fully, proceed as follows:
• Press in circlip to release lines.

🔧 Engine codes this applies to

📋 Procedure

1. ⚠ Secure earth wire of fuel extractorVAS 5190 to a bare metal part of the body. — Remove cotter (2) from shaft (1) of fuel extractorVAS 5190.
2. Use insulating tape to mark the extraction hose (arrow) at a distance of (a) = 1180 mm from the end of the hose.
3. Remove filler cap from fuel tank filler neck.
4. Screw shaft end (1) of fuel extractor unitVAS 5190 onto fuel filler neck.
5. 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).]

6. Empty fuel tank as far as possible.
7. Carefully pull out extraction hose. [Note: When no more fuel can be extracted, the tank is emptied just enough for fuel delivery unit to be removed without danger.If the fuel tank has to be drained fully, proceed as follows:]
8. Switch off ignition and all electrical consumers and remove ignition key.
9. Remove bench seat General body repairs, interior72Rear seats; Removing and installing bench seat.
10. Unclip cover (1) from fuel delivery unit. Arrow (2) points in direction of travel.
11. ⚠ The fuel system is pressurised!Wear eye protection and protective clothing to avoid possible injury and skin contact.Before loosening line connections, wrap a cloth around the connection. Then release pressure by carefully pulling off line. — Pull off 5-pin connector (1), black supply line (2) and blue return line (3). [Note: Press in circlip to release lines.]
12. Open locking ring using wrench T10202.
13. Pull fuel delivery unit out slightly.
14. Insert extraction hose of fuel extractorVAS 5190 as deeply as possible into fuel tank and extract fuel.

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