Emptying fuel tank when fuel pump is intact, engine codes CAYC, CAYB — VW

🧭 Before you start

Fits: VW Touran I (1T, 2003–2015)

• Special tools named: VAS 5190

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• The fuel pump is now activated. The vehicle diagnosis tester shows the progress of the drainage.
• Connections for fuel lines must engage »audibly« when joined.Take note of colour assignment when installing the connections !Ensure push-on coupling is secured properly by pulling it.Separate plug-in connectors .

🔧 Engine codes this applies to

📐 80 workshop diagrams for CAYB

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

📋 Procedure

1. Unscrew tip (1) from extraction hose of fuel extraction unit VAS 5190.
2. Screw fuel extraction adapterVAS 5190 /2 from fuel extraction adapter setVAS 5190 /10 onto extraction hose.
3. ⚠ Danger of burning from very hot fuel.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.Wear protective gloves.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. — Fold front right seat forwards as far as possible.
4. Fold rear bench seat forwards. Remove if necessary General body repairs, interior72Rear seat; Removing and installing bench seat / individual seats.
5. Unclip cover (1) for flange at retaining tabs (arrows), using removal wedge3409.

6. 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.
7. Disconnect the fuel supply line at the blind flange. Separate plug-in connectors .
8. Connect extraction hose with fuel extraction adapterVAS 5190 /2 to supply line connection of sealing flange.
9. Drain fuel tank with fuel extraction unitVAS 5190 through the supply line connection of sealing flange.
10. 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.]
11. Open shut-off tap on fuel extractorVAS 5190 until fuel tank is emptied. [Note: Connections for fuel lines must engage »audibly« when joined.Take note of colour assignment when installing the connections !Ensure push-on coupling is secured properly by pulling it.Separate plug-in connectors .]

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