VW t5 Fuel System Diesel Engines Eng

Service
Workshop Manual
Transporter 2004 ➤
Transporter 2010 ➤
Fuel supply system - Diesel engines
Engine ID AXB AXC BRR BRS AXD AXE BLJ BNZ BPC
CAA CAA CAA CAA CCH CCH CFC CAA
A B C E A B A D
Edition 09.2018
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
20 - Fuel supply system
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Transporter 2004 ➤ , Transporter 2010 ➤
Fuel supply system - Diesel engines - Edition 09.2018
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Safety regulations for working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1 Procedure should vehicle be misfueled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1 Procedure should vehicle be misfueled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1 Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3 Fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.1 Removing and installing fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . 25
3.2 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4 Plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.1 Separating plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5 Fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.1 Removing and installing fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.1 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.2 Bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7 Accelerator pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.1 Assembly overview - accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8 Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8.1 Checking fuel system pressurisation pump G6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8.2 Removing and installing tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8.3 Checking tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
8.4 Supplementary fuel pump V393 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Contents i
ii Contents
00 – Technical data
1 Identification
(VRL011977; Edition 09.2018)
⇒ “1.1 Engine number/engine data”, page 1
1.1 Engine number/engine data

The engine number -arrow- (“engine code” and “serial number”)
can be found at the joint between engine and gearbox.
The engine number consists of up to 9 characters (alphanumeric).
The first part (maximum 3 characters) makes up the “engine
code”, and the second part (6 characters), the “serial number”. If
more than 999,999 engines were produced with the same code
letters, the first of the six digits is replaced by a letter.
In addition, there is a sticker on the toothed belt guard with “engine
code” and “serial number”.
Or
Additionally there is a sticker on the front of the cylinder head with
“Engine code” and “Serial number”.
The engine code is also included on the vehicle data sticker.
Codes AXB AXC BRR BRS

Manufactured 03.03 ► 03.03 ► 01.06 ► 01.06 ►
Exhaust emissions fulfil EU3 EU3 EU4 EU4
Displacement l 1.9 1.9 1.9 1.9
Power kW at rpm 77/3500 63/3500 62/3500 75/3500
Torque Nm at rpm 250/2000 200/1600 …2400 200/2000 250/2000
Bore ∅ mm 79.5 79.5 79.5 79.5
Stroke mm 95.5 95.5 95.5 95.5
Compression ratio 18.0 18.0 18.0 18.0
CN min. 51 51 51 51
Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
Exhaust gas recirculation Yes Yes Yes Yes
Charging Yes Yes Yes Yes
Particulate filter No No Yes (also availa‐ Yes (also availa‐
ble without partic‐ ble without partic‐
ulate filter) ulate filter)
Charge air cooling Yes Yes Yes Yes
Codes AXD AXE BLJ BNZ BPC

Manufactured 01.03 ► 01.03 ► 08.03 ► 01.06 ► 01.06 ►
Exhaust emis‐ EU3 stand‐ EU3 stand‐ EU3 stand‐ EU4 stand‐ EU4 stand‐
sions fulfil ard ard ard ard ard
Displacement l 2.5 2.5 2.5 2.5 2.5
Power kW at rpm 96/3500 128/3500 120/3500 96/3500 128/3500
Torque Nm at rpm 340/2000 400/2000 400/2000 340/2000 … 400/2000 …
2300 2300
Bore ∅ mm 81.0 81.0 81.0 81.0 81.0
Stroke mm 95.5 95.5 95.5 95.5 95.5
1. Identification 1
Codes AXD AXE BLJ BNZ BPC

Compression ratio 18.5 18.5 18.5 18.5 18.5
CN min. 51 51 51 51 51
Firing order 1-2-4-5-3 1-2-4-5-3 1-2-4-5-3 1-2-4-5-3 1-2-4-5-3
Catalytic converter Yes Yes Yes Yes Yes
Exhaust gas recirculation Yes Yes Yes Yes Yes
Charging Yes Yes Yes Yes Yes
Charge air cooling Yes Yes Yes Yes Yes
Vehicles with four digit engine codes

Four-place engine codes are being introduced, starting with letter
“C”. The first 3 places show the mechanical design of engine and
are stamped on the engine as previously. The fourth digit denotes
the performance and torque rating of the engine and depends on
the engine control unit - J623- . The four-digit engine code can be
found on the identification plate, the vehicle data sticker and on
the engine control unit.
Codes CAAA CAAB CAAC CAAE
Manufactured from 05.09 ► 05.09 ► 05.09 ► 05.10 ►
to
Exhaust emissions fulfil EU4 standard EU3 standard EU5 standard EU5 standard
EU5 standard EU4 standard
EU5 standard
Power kW at rpm 62/3500 75/3500 103/3500 100/3500
Torque Nm at rpm 220/ 250/ 340/ 340/
1250 - 2500 1500 - 2500 1750 - 2500 1750 - 2500
Displacement cm3 1968 1968 1968 1968
Bore ∅ mm 81.0 81.0 81.0 81.0
Stroke mm 95.5 95.5 95.5 95.5
Valves per cylinder 4 4 4 4
Fuel: acc. to DIN EN 590 DIN EN 590 DIN EN 590 DIN EN 590
Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
Balancer shaft module No No yes/no 1) No
Catalytic converter Yes Yes Yes Yes
Particulate filter yes, for EU5 yes, for EU5 yes, for EU5 yes, for EU5
Particulate filter no, for EU4 no, for EU3 and No —
EU4
Selective catalytic reduction No No No No
(SCR system)
1)present in the case of engines compliant with EU5 standard
and/or in conjunction with dual clutch gearbox
Codes CCHA CCHB CFCA CAAD

Manufactured from 05.09 ► 05.10 ► 05.09 ► 05.11 ►
to
2 Rep. gr.00 - Technical data

Codes CCHA CCHB CFCA CAAD

Exhaust emissions fulfil EU5 standard EU5 standard EU5 standard EU5 standard
Power kW at rpm 103/3500 100/3500 132/4000 84/3500
Torque Nm at rpm 340/ 340/ 400/ 250/
1750 - 2500 1750 - 2500 1500 - 2000 1500 - 2500
Displacement cm3 1968 1968 1968 1968
Bore ∅ mm 81.0 81.0 81.0 81.0
Stroke mm 95.5 95.5 95.5 95.5
Valves per cylinder 4 4 4 4
Fuel: acc. to DIN EN 590 DIN EN 590 DIN EN 590 DIN EN 590
Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
Balancer shaft module yes/no 1) Yes Yes No
Catalytic converter Yes Yes Yes Yes
Particulate filter yes, for EU5 yes, for EU5 yes, for EU5 yes, for EU5
Particulate filter — — no, for EU3 and —
EU4
Selective catalytic reduction No No No No
(SCR system)
1)present in the case of engines compliant with EU5 standard
and/or in conjunction with dual clutch gearbox
Volkswagen Technical Site: http://vwts.ru http://vwts.info
1. Identification 3
2 Safety information
⇒ “2.1 Safety regulations for working on fuel supply”, page 4
2.1 Safety regulations for working on fuel

supply
Caution
When performing any repair work, especially in the engine

compartment, pay attention to the following due to the cramped
conditions:
♦ Route all the various lines and electrical wiring so that they
are in their original positions.
♦ Ensure that there is sufficient clearance to all moving or
hot components.
♦ The fuel and the fuel lines in the fuel system can become
very hot (danger of scalding)!
WARNING
The fuel line is under pressure.

Fuel poses danger of injury to eyes and skin.
Wear protective goggles and protective clothing to avoid injury
and contact with the skin. Wrap a cloth around the connection
before loosening hose connections. Then reduce pressure by
carefully opening the connection.
When removing and installing fuel gauge sender or fuel pump

(fuel delivery unit) from a full or partly full fuel tank, observe the
following:
♦ Even before work starts, the extraction hose of a fume extrac‐
tion system which is switched on must be placed in the vicinity
of the assembly opening of the fuel tank to extract any escap‐
ing fumes. If no exhaust gas extraction system is available, a
radial fan with a displacement greater than 15 m3/h can be
used providing that motor is not in air flow.
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!

3 Repair instructions
⇒ “3.1 Rules for cleanliness”, page 5
⇒ “3.2 General information”, page 5
3.1 Rules for cleanliness

When working on the fuel supply/injection system, carefully follow
the “6 rules” below:
♦ Thoroughly clean all joints and surrounding areas before dis‐
mantling.
♦ Place removed parts on a clean surface and cover them over.
Use lint-free cloths only.
♦ Carefully cover opened components or seal them if repairs
cannot be carried out immediately.
♦ Install only clean parts; do not remove new parts from pack‐
aging until immediately before installing. Do not use parts that
have been kept unpackaged (for example in toolboxes).
♦ If system is open, do not work with compressed air. Do not
move the vehicle.
♦ Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.
3.2 General information
3.2.1 General notes on fuel supply system
Note
♦ Hose connections are secured with either spring-type or

clamp-type clips.
♦ Always renew clamp-type clips with spring-type clips.
♦ When installing or removing spring-type clips, we recommend
using spring-type clip pliers - VAS 6340- or
♦ hose clip pliers - VAS 6362- are recommended.
3. Repair instructions 5
3.2.2 General notes on fuel system

To prevent the high-pressure fuel pump from running while it is
empty and to ensure that the engine starts quickly after parts have
been renewed, it is important to observe the following:
♦ If fuel system components between fuel tank and fuel high-
pressure pump are removed or renewed, initial fuel filling must
be carried out.
♦ If a fuel pump, fuel line (between fuel tank and fuel high-pres‐
sure pump) or fuel filter is removed or renewed
♦ Fuel system must be bled before starting engine for first time.
♦ If the high-pressure fuel pump is removed or renewed, the fuel
system must be bled before engine is started for the first time.
♦ Initial fuel filling procedure ⇒ Vehicle diagnostic tester.
• Clean tools and workbench etc. before working on injection
system.
• Thoroughly clean all joints and surrounding areas before dis‐
mantling.
• When removing components, plug all open connections im‐
mediately with suitable, clean sealing caps.
• Do not remove sealing caps from components until immedi‐
ately prior to installation. Place removed components in new
sealable plastic bags (if available, use original packaging of
new components).
• Before installation, check injectors and their surroundings vis‐
ually; they must be undamaged and free of lint. Ensure that
the injector bore is clean.
• Only cleaning set - VAS 6811- may be used for cleaning the
sealing surface of the injector bore.
• For detailed information on how to use the cleaning set as well
as the order in which its components are applied, refer to the
⇒ operating manual provided with the cleaning set - VAS
6811- .
• If high-pressure lines are not renewed, they must be labelled
on removal. High-pressure fuel lines must always be re-instal‐
led in their original positions (i.e. on the same cylinder).
• The following components and seals/O-rings must always be
renewed when the injectors are removed and installed: “cop‐
per seal”, “O-ring for injector bore”, “O-ring for injector return
connection”, “injector return connection clip”
• The following components and seals/O-rings must always be
renewed when an injector is renewed: “copper seal”, “O-ring
for injector shaft” and “O-ring for injector return connection”
“injector return clip”
• Always fit new copper seals for the injectors. Check all new O-
rings for damage before installing. O-rings must be moist when
installed (assembly oil or clean engine oil). Use assembly tool
to install the “O-ring for injector return connection”.
• Take care not to damage the injectors when removing the old
copper seals.
• Align high-pressure lines free from tension. First tighten all
unions hand-tight and then tighten to torque.
• Never attempt to reshape high-pressure fuel lines.
• When working on any parts of the high-pressure fuel system,
tools may only be used for loosening and tightening pipe un‐

ions. All other components must always be removed and

installed by hand without using tools or other equipment.
• Disassembling individual common rail components is not per‐
mitted.
• The components should be replaced as complete units if faul‐
ty.
• Never attempt to bleed the common rail system by loosening
high-pressure components after starting the engine.
• Do not carry out any installation work on common rail system
whilst engine is running.
• In particular, do not open or release high-pressure lines and
electrical connectors.
• All cable ties which were opened or cut open during removal
must be replaced with new ties in same position during instal‐
lation.
• When the fuel system is open: do not work with compressed
air if this can be avoided. Try not to move the vehicle.
• Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.
3. Repair instructions 7
20 – Fuel supply system

1 Procedure should vehicle be misfu‐
eled
⇒ “1.1 Procedure should vehicle be misfueled”, page 8
1.1 Procedure should vehicle be misfueled

Special tools and workshop equipment required
♦ Fuel identification unit - VAS 6774-
Note
♦ Misfuelling can cause irreversible damage to the high-pres‐

sure components, particularly the high-pressure pump, due to
the lack of lubrication otherwise provided by diesel fuel.
♦ Damage due to seizure and metal particles can be expected.
♦ These particles can also cause further damage in the pressure
control valve and injectors.
♦ If in any doubt regarding the fuel quality, take a sample and
analyse the fuel with the fuel analysis unit - VAS 6774- ⇒ op‐
erating instructions .
♦ The fuel analysis unit - VAS 6774- is no substitute for a labo‐
ratory test in warranty cases.
These instructions are intended as a guide through the individual

work steps by means of a flowchart, while bearing various condi‐
tions in mind.
Was the engine started with the incorrect fuel?
Yes
⇒ “1.1.1 Step 1, engine was started with incorrect fuel”,
page 9 .
No
⇒ “1.1.2 Step 2, engine was not started with incorrect fuel”,
page 9 .
8 Rep. gr.20 - Fuel supply system

⇒ “1.1.1 Step 1, engine was started with incorrect fuel”,

page 9
⇒ “1.1.2 Step 2, engine was not started with incorrect fuel”, page
9
⇒ “1.1.3 Step 3, swarf in fuel delivery unit GX1 and fuel tank”,
page 10
⇒ “1.1.4 Step 4, no swarf in fuel delivery unit GX1 and fuel tank”,
page 11
⇒ “1.1.5 Step 5, there are metal particles in high-pressure pump”,
page 11
⇒ “1.1.6 Step 6, there are no metal particles in high-pressure
pump”, page 11
1.1.1 Step 1, engine was started with incorrect

fuel
Procedure
– If fitted, disconnect electrical connector of supplementary fuel
pump - V393- .
– Remove fuel tank ⇒ page 18 .
– Remove fuel delivery unit - GX1- , and drain ⇒ page 25 .
– Drain fuel pump reservoir of fuel delivery unit - GX1- .
– Drain fuel tank ⇒ page 18 .
– Check fuel tank for metal particles.
– Carry out a visual inspection for foreign bodies and metal par‐
ticles in fuel pump reservoir and on preliminary filter.
Metal particles found?
Yes
⇒ “1.1.3 Step 3, swarf in fuel delivery unit GX1 and fuel tank”,
page 10 .
No
⇒ “1.1.4 Step 4, no swarf in fuel delivery unit GX1 and fuel
tank”, page 11 .
1.1.2 Step 2, engine was not started with in‐

correct fuel
Procedure
– Remove fuel delivery unit - GX1- , and drain ⇒ page 25 .
– Check strainer and clean if soiled.
– Drain fuel tank ⇒ page 18 .
Fuel tank completely empty:
– Clean inside of fuel tank with lint-free cloth.
– Install fuel delivery unit - GX1- ⇒ page 25 .
– Install fuel tank ⇒ page 18 .
– Fill fuel tank with 5 litres of diesel fuel.
– Perform bleed fuel system function using ⇒ Vehicle diagnostic
tester.
1. Procedure should vehicle be misfueled 9

Note
This process takes 130 seconds. Fuel pumps are actuated a total
of 3 times in the process. The process must not be terminated
prematurely.
– Renew fuel filter ⇒ page 33 .

– Fill up vehicle.
– Carry out road test.
1.1.3 Step 3, swarf in fuel delivery unit - GX1-

and fuel tank
♦ Diesel extractor - VAS 5226-
Procedure
– Clean fuel delivery unit - GX1- and fuel tank using diesel ex‐
tractor - VAS 5226- .
– Install fuel delivery unit - GX1- ⇒ page 25 .
– Completely empty fuel tank again as described above
⇒ page 9 .
Renew following high-pressure components:
♦ High-pressure pump ⇒ Rep. gr. 23 ; High-pressure pump;
Removing and installing high-pressure pump .
♦ High-pressure lines ⇒ Rep. gr. 23 ; Injectors/fuel rail; Re‐
moving and installing high-pressure lines .
♦ Fuel rail including fuel pressure regulating valve - N276- and
fuel pressure sender - G247- ⇒ Rep. gr. 23 ; Injectors/fuel
rail; Removing and installing fuel rail
♦ Injectors ⇒ Rep. gr. 23 ; Injectors/fuel rail (fuel rail); Removing
and installing injectors
♦ Fuel return lines (overflow oil lines) ⇒ Rep. gr. 23 ; Injector
units/fuel rail; Assembly overview - injectors .
♦ Fuel filter: Renew ⇒ page 33
– Bleed fuel system ⇒ Rep. gr. 23 ; Injection system; Filling/
bleeding fuel system .

1.1.4 Step 4, no swarf in fuel delivery unit -

GX1- and fuel tank
Procedure
– Completely empty fuel tank again as described above
⇒ page 9 .
– Disconnect electrical connector.
– Unscrew bolts -arrows-.
– Detach fuel metering valve - N290- -A-.
– Check fuel metering valve - N290- -A- and high-pressure
pump for metal particles.
Metal particles found?
Yes
⇒ “1.1.5 Step 5, there are metal particles in high-pressure
pump”, page 11 .
No
⇒ “1.1.6 Step 6, there are no metal particles in high-pressure
pump”, page 11 .
1.1.5 Step 5, there are metal particles in high-

pressure pump
Procedure
– Replace high-pressure pump ⇒ Rep. gr. 23 ; High-pressure
pump: Removing and installing high-pressure pump .
– Renew high-pressure lines ⇒ Rep. gr. 23 ; Injectors/fuel rail
(fuel rail): Removing and installing high-pressure lines .
– Renew fuel rail including fuel pressure regulating valve - N276-
and fuel pressure sender - G247- ⇒ Rep. gr. 23 ; Injectors/
fuel rail: Removing and installing fuel rail .
– Renew injectors ⇒ Rep. gr. 23 ; Injectors/fuel rail; Removing
and installing injectors
– Renew fuel return lines ⇒ Rep. gr. 23 ; Injector units/fuel rail;
Assembly overview - fuel rail
– Fill/bleed fuel system ⇒ Rep. gr. 23 ; Injection system; Filling/
1.1.6 Step 6, there are no metal particles in

high-pressure pump
Procedure
– Replace high-pressure pump ⇒ Rep. gr. 23 ; High-pressure
pump: Removing and installing high-pressure pump .
– Fill/bleed fuel system ⇒ Rep. gr. 23 ; Injection system; Filling/
1. Procedure should vehicle be misfueled 11


2 Fuel
⇒ “2.1 Assembly overview - fuel tank”, page 13
⇒ “2.2 Removing and installing fuel tank”, page 18
2.1 Assembly overview - fuel tank

⇒ “2.1.1 Assembly overview – fuel tank, engine codes AXB, AXC,
BRR, BRS, AXD, AXE, BLJ, BNZ, BPC”, page 13
⇒ “2.1.2 Assembly overview – fuel tank, engine codes CAAA,
CAAB, CAAC, CAAD, CAAE, CCHA, CCHB, CFCA”, page 15
2.1.1 Assembly overview – fuel tank, engine codes AXB, AXC, BRR, BRS, AXD,
AXE, BLJ, BNZ, BPC
1 - Fuel
Caution
It• is not permissible to
empty the fuel tank with
the fuel suction device -
VAS 5190- via the filler
neck because doing so
will cause damage to the
non-return valve
⇒ page 15 .
If• the fuel tank is to be
emptied, the fuel system
pressurisation pump -
G6- and fuel gauge send‐
er - G- must first be
removed, whereupon the
fuel tank can be emptied
through the ensuing
aperture.
❑ Removing and installing

⇒ page 18
❑ Drain fuel tank using
fuel extractor - VAS
5190-
2 - Bush
3 - Earth connection
❑ Ensure firm seating
4 - Seal
❑ Renew if damaged
❑ Moisten with fuel when
installing
5 - Fuel delivery unit
❑ (Fuel system pressurisation pump - G6- )
❑ Note installation position on fuel tank ⇒ page 15
❑ To remove, first remove fuel tank ⇒ page 18 .
❑ With fuel gauge sender - G-
❑ Removing and installing fuel gauge sender - G- ⇒ page 26
6 - Union nut
❑ Remove and install using union nut tool - 3217- .
2. Fuel 13
❑ 80 Nm
7 - Supply line
❑ To fuel filter ⇒ page 33 or ⇒ page 65
❑ Clipped onto fuel tank
❑ black
❑ To pull off flange, press release button on connecting piece.
8 - Return line
❑ From fuel cooler
❑ Blue or with blue marking
9 - Bolt
❑ 12 Nm
10 - Rubber cup
11 - Securing bolt
12 - Cap
❑ Renew seal if damaged.
13 - Bolts
❑ Renew after removal
❑ 26 Nm
14 - Securing strap
❑ Observe installation position
15 - Return line
❑ From fuel filter ⇒ page 33 or tandem pump
❑ Blue or brown
16 - Fuel cooler
❑ Removing and installing ⇒ page 31
❑ Not in case of vehicles without fuel preheating
17 - Return line
❑ Blue or brown
18 - Wiring harness

Non-return valve -arrow- in filler neck
Installation position of fuel gauge sender - G-

Marking on flange of fuel gauge sender - G- must align with mark‐
ing on fuel tank -arrows-.
Connections for blue or blue-marked return line -1- and black
supply line -2- are marked with an arrow on flange of fuel gauge
sender - G- .
Note
After installing the fuel gauge sender - G- , check whether fuel

supply and fuel return lines are still clipped onto the fuel tank.
2.1.2 Assembly overview – fuel tank, engine codes CAAA, CAAB, CAAC, CAAD,
CAAE, CCHA, CCHB, CFCA
2. Fuel 15
1 - Fuel
Caution
It• is not permissible to
empty the fuel tank with
the fuel suction device -
VAS 5190- via the filler
neck because doing so
will cause damage to the
non-return valve
⇒ page 17 .
If• the fuel tank is to be
emptied, the fuel system
pressurisation pump -
G6- and fuel gauge send‐
er - G- must first be
removed, whereupon the
fuel tank can be emptied
through the ensuing
aperture.

⇒ page 21
2 - Bush
3 - Earth connection
4 - Seal
❑ Renew if damaged
❑ Moisten with fuel when
installing
5 - Fuel delivery unit
❑ (Fuel system pressuri‐
sation pump - G6- )
❑ Note installation posi‐
tion on fuel tank ⇒ page 17
❑ To remove, first remove fuel tank ⇒ page 65 .
❑ With fuel gauge sender - G-
❑ Removing and installing fuel gauge sender - G- ⇒ page 26
6 - Union nut
❑ Remove and install using union nut tool - 3217- .
❑ 80 Nm
7 - Supply line
❑ To fuel filter ⇒ page 65 .
❑ black
❑ To pull off flange, press release buttons on connecting piece
8 - Return line
❑ Only in vehicles with auxiliary heater
❑ Blue marking

9 - Bolt
❑ 11 Nm
10 - Rubber cup
❑ During installation, fit rubber cup in the body until it latches fully into place at the top and bottom
11 - Securing bolt
12 - Cap
❑ Renew seal if damaged.
13 - Bolts
❑ 26 Nm
14 - Securing strap
❑ Observe installation position
15 - Return line
❑ From fuel filter ⇒ page 65 .
❑ Blue or brown
Installation position of fuel gauge sender - G-

sender - G- .
Note
After installing fuel gauge sender - G- , check whether fuel supply

and fuel return lines are still clipped onto the fuel tank.
2. Fuel 17
2.2 Removing and installing fuel tank

⇒ “2.2.1 Removing and installing fuel tank, engine codes AXB,
AXC, BRR, BRS, AXD, AXE, BLJ, BNZ, BPC”, page 18
⇒ “2.2.2 Removing and installing fuel tank, engine codes CAAA,
CAAB, CAAC, CAAD, CAAE, CCHA, CCHB, CFCA”, page 21
2.2.1 Removing and installing fuel tank, en‐

gine codes AXB, AXC, BRR, BRS, AXD,
AXE, BLJ, BNZ, BPC
WARNING
Risk of explosion of fuel tank. If a new or completely empty fuel

tank has been installed, it must be filled immediately with at
least 5 litres of fuel. The fuel pump must not be allowed to run
when the fuel tank is empty.
Special tools and workshop

equipment required
♦ Key for union nut - 3217-

♦ Torque wrench - V.A.G 1331-


♦ Engine and gearbox jack - V.A.G 1383 A- discontinued, use
engine and gearbox jack - VAS 6931-
♦ Fuel extractor - VAS 5190-
Removing
Caution
• It is not permissible to empty the fuel tank with the fuel

suction device - VAS 5190- via the filler neck.
♦ If the fuel tank is emptied with the fuel suction device - VAS
5190- via the filler neck, the non-return valve -arrow- will
be damaged.

– Note safety precautions before starting installation work
⇒ page 4 .
– Observe rules for cleanliness ⇒ page 5 .
Note
The battery earth must be disconnected for the remaining proce‐

dure. For this reason, check whether a coded radio is fitted. Then
obtain anti-theft coding first if necessary.
– Open fuel tank flap and remove fuel tank cap.

– Clean area around fuel filler neck.
– Remove securing bolt, then pull rubber cup off filler neck and
remove.
– Unscrew securing bolt of filler neck.
– Remove lower cover with heat shield -A-.

– If necessary, remove outer underbody cover on front left as
well as underbody cover on rear left ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody cover
2. Fuel 19
– Detach fuel supply line -1- and fuel return line -2-.
Note
♦ Press in buttons on hose couplings to do this.

♦ On vehicles with auxiliary heater disconnect additional fuel
line.
– Remove fuel cooler if there is one.

– Remove securing straps. When doing this, support fuel tank
with engine and gearbox jack - VAS 6931- .
– Lower engine and gearbox jack - VAS 6931- just enough to
allow connector to be pulled off fuel pump flange.
– Pull connector off fuel pump flange and unclip wire from fuel
tank.
– Lower fuel tank.
If necessary:
– Remove fuel delivery unit ⇒ page 13 .
– Use the fuel suction device - VAS 5190- to completely empty
the fuel tank via the fuel delivery unit.
Installing
Installation is carried out in the reverse order. When installing,
note the following:
WARNING

♦ Connections for breather and fuel lines must engage audibly

when joined.
♦ Clip fuel lines onto fuel tank.
♦ Push connector onto fuel pump flange and clip wire onto fuel
tank.
♦ Ensure fuel hoses are seated correctly.
♦ Install fuel tank using tensioning straps and new bolts.
Specified torques
♦ ⇒ “2.1.1 Assembly overview – fuel tank, engine codes AXB,
AXC, BRR, BRS, AXD, AXE, BLJ, BNZ, BPC”, page 13

2.2.2 Removing and installing fuel tank, en‐

gine codes CAAA, CAAB, CAAC,
CAAD, CAAE, CCHA, CCHB, CFCA
WARNING


equipment required

♦ Engine and gearbox jack - V.A.G 1383 A- discontinued, use
engine and gearbox jack - VAS 6931-
2. Fuel 21
Removing
Caution
• It is not permissible to empty the fuel tank with the fuel

suction device - VAS 5190- via the filler neck.
• If the fuel tank is to be emptied, the fuel system pressuri‐
sation pump - G6- and fuel gauge sender - G- must first
be removed, whereupon the fuel tank can be emptied
through the ensuing aperture.
♦ If the fuel tank is emptied with the fuel suction device - VAS
5190- via the filler neck, the non-return valve -arrow- will
be damaged.

– Note safety precautions before starting installation work
⇒ page 4 .
Note
The battery earth must be disconnected for the remaining proce‐

dure. Before doing so, check whether a coded radio is fitted in the
vehicle. Then obtain anti-theft coding first if necessary.
– Open fuel filler flap and unscrew cap.

– Clean area around fuel filler neck.
– Loosen bolt, then pull rubber cup off filler neck, and remove it.
– Remove earth wire.
– Unscrew bolt of filler neck.
– Remove front left underbody cladding -arrow-.

– Remove middle left underbody cladding -arrow-.
– Press securing ring to release fuel lines and then detach fuel
supply line -1- and return line -2-.
Vehicles with auxiliary heater
– Remove clip -5-.
– Pull hose -6- off the fuel line -3-.
Continued for all vehicles
– Remove securing straps. When doing this, support fuel tank
with engine and gearbox jack - VAS 6931- .
– Lower engine and gearbox jack - VAS 6931- just enough to
allow connector to be pulled off fuel pump flange.
– Pull connector off fuel pump flange and unclip wire from fuel
tank.
– Unclip wiring harness -1- from fuel tank.

– Lower fuel tank.
If the fuel tank is to be replaced:
– Unclip and remove supply line -2- and return line -3- from fuel
tank.
– If vehicle has an auxiliary heater, unclip and remove fuel line
-4- from fuel tank.
If necessary:
– Use the fuel suction device - VAS 5190- to completely empty
the fuel tank via the fuel delivery unit.
Installing
Install in reverse order of removal, observing the following:
WARNING

– Install fuel tank using tensioning straps and new bolts.

– Push connector onto fuel pump flange and clip wire onto fuel
tank.
2. Fuel 23
– Clip fuel lines -2- to -4- onto fuel tank.

– Clip wiring harness -1- onto fuel tank.
– Connect fuel supply line -1- and return line -2-. Connections
for fuel lines must engage audibly when joined.
– Push hose -6- onto fuel line -3- as far as the mark -4-.
– Fit left underbody cover ⇒ General body repairs, exterior; Rep.
gr. 66 ; Underbody cover .
Specified torques
♦ ⇒ “2.1.2 Assembly overview – fuel tank, engine codes CAAA,
CAAB, CAAC, CAAD, CAAE, CCHA, CCHB, CFCA”,
page 15

3 Fuel delivery unit, fuel gauge sender

⇒ “3.1 Removing and installing fuel delivery unit, fuel gauge send‐
er”, page 25
⇒ “3.2 Removing and installing fuel gauge sender G ”,
page 26
3.1 Removing and installing fuel delivery

unit, fuel gauge sender
⇒ “3.1.1 Removing and installing fuel delivery unit/fuel gauge
sender, engine codes CAAA, CAAB, CAAC, CAAD, CAAE,
CCHA, CCHB, CFCA”, page 25
3.1.1 Removing and installing fuel delivery

unit/fuel gauge sender, engine codes
CAAA, CAAB, CAAC, CAAD, CAAE,
CCHA, CCHB, CFCA
Removing
– Release connections for blue or blue-marked return line -1-
and black supply line -2- and pull from fuel pump unit.
– Release connector -3- and remove it from fuel delivery unit.
3. Fuel delivery unit, fuel gauge sender 25

– Unscrew union nut with union nut tool - 3217- .

– Take fuel delivery unit out of the fuel tank.
Installing

sender - G- .
Specified torques
♦ ⇒ “2.1.2 Assembly overview – fuel tank, engine codes CAAA,
CAAB, CAAC, CAAD, CAAE, CCHA, CCHB, CFCA”,
page 15
3.2 Removing and installing fuel gauge

sender - G-
Removing
– Remove fuel system pressurisation pump - G6- .
– Release connector lugs on lines -3- and -4- and pull off.
– Lift tabs -1- and -2- using a screwdriver, and pull off fuel gauge
sender - G- downwards -arrows-.
Installing
– Insert fuel gauge sender - G- into guides on fuel pump - G6- ,
and press upwards until it engages.
Specified torques
♦ ⇒ “2.1 Assembly overview - fuel tank”, page 13

4 Plug-in connectors
⇒ “4.1 Separating plug-in connectors”, page 27
4.1 Separating plug-in connectors

♦ Lever - T10468-
– Note safety precautions before starting work.

Assignment of plug-in connectors
Note
♦ The plug-in connectors for fuel, vacuum and breather lines are
colour coded. There is either a coloured dot on the plug-in
connector or the release button is of the respective colour
⇒ page 27 .
♦ Plug-in connectors for fuel lines must engage »audibly« when
joined.
♦ Ensure plug-in connector is secured properly by pulling it.
Colour assignment
Plug-in connector Colour code on plug-in connector
Fuel supply black
Fuel return line blue
Breather White, beige
Vacuum green
WARNING
The fuel line is under pressure.

Fuel poses danger of injury to eyes and skin.
Wear protective goggles and protective clothing to avoid injury
and contact with the skin. Wrap a cloth around the connection
before loosening hose connections. Then reduce pressure by
carefully opening the connection.
4. Plug-in connectors 27
Version 1
Plug-in connector with release buttons -arrows- on right and left
Open
Counterhold at the coupling point for fuel -1- in the engine com‐
partment.
– Insert lever - T10468- between heat shield and stop -arrow- of
fuel line -2- and counterhold.
Continued for all coupling points in fuel system:

– Push plug-in connector -1- in -direction of arrow A-.
– Press and hold release buttons.
– Pull plug-in connector -1- off fuel line -2- in
-direction of arrow B-.
Note colour assignment during installation ⇒ page 27 .
Plug-in connectors for fuel lines must engage »audibly« when
joined.
– Ensure plug-in connector is secured properly by pulling it.

Version 2
Plug-in connector with pull-release mechanism -arrow-.
Open
– Push plug-in connector -1- in -direction of arrow A-.
– Pull pull-release mechanism -2- in -direction of arrow B-.
– Pull plug-in connector -1- off fuel line -3- in
-direction of arrow B-.
joined.
Version 3
Plug-in connector with button in front -arrow-
Open
– Press release button -arrow- and pull off plug-in connectors.
joined.
Version 4
Plug-in connector with release button -arrows- on right and left:
Open
– Push plug-in connector in -direction of arrow A-.
– Press release buttons -arrows- and pull off plug-in connector.
joined.
4. Plug-in connectors 29
Version 5
Plug-in connector with release buttons -arrows- on right and left:
Open
joined.
Version 6
Plug-in connector with release buttons -arrows- on right and left:
Open
– Push plug-in connector -1- in -direction of arrow- and maintain
pressure.
joined.
Version 7
Plug-in connector -1- with release buttons -2- on right and left:
Open
– Press plug-in connector -1- in -direction of arrow A- and main‐
tain pressure.
– Press release button -2- in -direction of arrow B- and pull off
plug-in connector -1-.
joined.

5 Fuel cooler
⇒ “5.1 Removing and installing fuel cooler”, page 31
5.1 Removing and installing fuel cooler

⇒ “5.1.1 Removing and installing fuel cooler, engine codes AXB,
AXC, BRR, BRS”, page 31
5.1.1 Removing and installing fuel cooler, en‐

gine codes AXB, AXC, BRR, BRS
On vehicles without fuel preheating a fuel cooler is not installed.
Removing
Observe rules for cleanliness ⇒ page 5 .
Note
The fuel cooler is located in the return line to fuel tank. It is located
on the vehicle underbody.
– Remove underbody cover ⇒ General body repairs, exterior;

Rep. gr. 66 ; Underbody cover .
– Unscrew securing bolts -arrows-.
5. Fuel cooler 31
– Pull fuel cooler downwards, and detach fuel lines -arrows- at

fuel cooler.
Installing
Specified torques
Component Specified torque
Securing bolts for fuel cooler 20 Nm

6 Fuel filter
⇒ “6.1 Assembly overview - fuel filter”, page 33
⇒ “6.2 Bleeding fuel system”, page 37
6.1 Assembly overview - fuel filter

⇒ “6.1.1 Assembly overview – fuel filter on vehicles with fuel pre-
heating, engine codes AXB, AXC, BRR, BRS”, page 33
⇒ “6.1.2 Assembly overview – fuel filter on vehicles with fuel pre-
heating, engine codes AXD, AXE, BLJ, BNZ, BPC”, page 35
⇒ “6.1.3 Assembly overview – fuel filter on vehicles without fuel
pre-heating, engine codes AXB, AXC, BRR, BRS, AXD, AXE,
BLJ, BNZ, BPC”, page 36
6.1.1 Assembly overview – fuel filter on vehi‐

cles with fuel pre-heating, engine codes
AXB, AXC, BRR, BRS
Note
The fuel system must be bled to guarantee immediate start of the

engine after renewing the fuel filter ⇒ Maintenance ; Booklet
19.1 .
6. Fuel filter 33
1 - Securing clip
2 - Return line
❑ To fuel cooler
⇒ page 31
❑ Clipped on fuel filter,
identification -RT-
❑ To pull off, press release
button on connection.
❑ Blue or with blue mark‐
ing
3 - Supply line
❑ From fuel tank
❑ Clipped on fuel filter,
identification -VF-
❑ black
4 - Bolt
❑ 18 Nm
5 - Bracket
6 - Nut
❑ 18 Nm
7 - Fuel filter
❑ Note installation posi‐
tion on bracket
⇒ Item 5 (page 34)
8 - Seal
9 - Water drain screw
❑ 4 Nm
10 - Supply line
❑ To tandem pump
❑ Clipped on fuel filter, identification -VM-
❑ To pull off, press release button on connection.
❑ black
11 - Return line
❑ From tandem pump
❑ Clipped on fuel filter, identification -RF-
❑ Blue or with blue marking


cles with fuel pre-heating, engine codes
AXD, AXE, BLJ, BNZ, BPC
Note
The fuel system must be bled after renewing the fuel filter
⇒ page 37 .
1 - Securing clip
2 - Return
❑ To fuel cooler
❑ Blue or with blue mark‐
ing
❑ Union with marking -
RT-.
3 - Supply
❑ From fuel tank
❑ black
VF-.
4 - Bolt
❑ 25 Nm
5 - Bracket
❑ For fuel filter
6 - Nut
❑ 25 Nm
7 - Fuel filter
❑ Observe change inter‐
vals.
❑ Observe installation po‐
sition
8 - Seal
9 - Water drainage connection
❑ 5 Nm
10 - Supply line
❑ To tandem pump
❑ Union with marking -VM-.
11 - Return line
❑ From tandem pump
6. Fuel filter 35
❑ Union with marking -RF-.

cles without fuel pre-heating, engine co‐
des AXB, AXC, BRR, BRS, AXD, AXE,
BLJ, BNZ, BPC
Note

19.1 .
1 - Supply hose
❑ To tandem pump
VM-.
2 - Supply line
❑ From fuel tank
❑ black
VF-.
3 - Fuel filter
❑ Observe change inter‐
vals.
❑ Observe installation po‐
sition
4 - Bracket
❑ For fuel filter
5 - Bolt
❑ 9 Nm
6 - Bolt/nut
❑ 18 Nm
7 - Bracket
8 - Bracket
❑ For fuel hoses

6.2 Bleeding fuel system

⇒ “6.2.1 Bleeding fuel system, engine codes AXB, AXC, BRR,
BRS, AXD, AXE, BLJ, BNZ, BPC”, page 37
⇒ “6.2.2 Bleeding fuel system, engine codes CAAA, CAAB,
CAAC, CAAD, CAAE, CCHA, CCHB, CFCA”, page 37
6.2.1 Bleeding fuel system, engine codes

AXB, AXC, BRR, BRS, AXD, AXE, BLJ,
BNZ, BPC
19.1 .
6.2.2 Bleeding fuel system, engine codes

CAAA, CAAB, CAAC, CAAD, CAAE,
CCHA, CCHB, CFCA
Caution
After new or removed parts such as the fuel filter or fuel lines
have been fitted, the high-pressure pump must be filled with
fuel before the engine is started for the first time again. It is
essential not to allow the high-pressure pump to run while still
empty.
Bleeding fuel system ⇒ Rep. gr. 23 ; Injection system .
6. Fuel filter 37
7 Accelerator pedal
⇒ “7.1 Assembly overview - accelerator module”, page 38
7.1 Assembly overview - accelerator module
1 - Mounting bracket
2 - Connector
❑ Black, 6-pin.
3 - Nut
❑ 10 Nm
4 - Acceleration pedal position
sender - G79-
❑ Not adjustable.
❑ The accelerator position
sender - G79- transmits
the driver's input to the
engine control unit
❑ Remove footwell cover
to remove sender.

8 Fuel pump
⇒ “8.1 Checking fuel system pressurisation pump G6 ”,
page 39
⇒ “8.2 Removing and installing tandem pump”, page 50
⇒ “8.3 Checking tandem pump”, page 55
⇒ “8.4 Supplementary fuel pump V393 ”, page 65
8.1 Checking fuel system pressurisation

pump - G6-
⇒ “8.1.1 Checking delivery pressure of fuel system pressurisation
pump G6 , engine codes AXD, AXE, BLJ, BNZ, BPC”,
page 39
⇒ “8.1.2 Checking delivery pressure of fuel system pressurisation
pump G6 , engine codes CAAA, CAAB, CAAC, CAAD, CAAE,
⇒ “8.1.3 Checking delivery rate of fuel system pressurisation
page 42
⇒ “8.1.4 Checking delivery rate of fuel system pressurisation
⇒ “8.1.5 Checking voltage supply of fuel system pressurisation
page 45
⇒ “8.1.6 Checking voltage supply of fuel system pressurisation
⇒ “8.1.7 Checking current draw of fuel system pressurisation
page 47
⇒ “8.1.8 Checking current draw of fuel system pressurisation
8.1.1 Checking delivery pressure of fuel sys‐

tem pressurisation pump - G6- , engine
codes AXD, AXE, BLJ, BNZ, BPC
8. Fuel pump 39
♦ Pressure tester (diesel) - VAS 6551-
♦ Vehicle diagnostic tester

Test conditions
• Fuses must be OK.
• Battery voltage at least 12 V
• All electrical consumers, e.g. lights and rear window heating,
must be switched off.
• Fuel filter and fuel lines must not be blocked.
Procedure
– Remove front left underbody cover ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody cover .
– Press the circlip to release the fuel line and then detach the
fuel supply line -1-.
– Connect pressure tester (diesel) - VAS 6551- to open ends of
fuel supply line -1- using suitable lines.
– Switch on pressure tester (diesel) - VAS 6551- by pressing
On/Off button.
– Open shut-off taps “A” and “B” of pressure tester and close
shut-off tap “C”.
– Start engine and allow to idle.
– Read pressure shown by pressure tester (diesel) - VAS 6551- .
Specification: at least 0.5 bar.
– Place pressure tester (diesel) - VAS 6551- onto windscreen
so that measured value can be read from inside vehicle.
– Increase idling speed to 2500 rpm, and read the indicated
pressure. Specification: at least 0.25 bar.
– If the delivery pressure temporarily drops, renew fuel delivery
unit ⇒ page 13 .
– If specifications are obtained, renew fuel filter to ensure the
fuel filter is not blocked.
– Check fuel pump delivery rate ⇒ page 42 .
8.1.2 Checking delivery pressure of fuel sys‐

tem pressurisation pump - G6- , engine
codes CAAA, CAAB, CAAC, CAAD,


Test conditions
Procedure
– Remove front left underbody cover -arrow- ⇒ General body
repairs, exterior; Rep. gr. 66 ; Underbody cover .
8. Fuel pump 41
– Connect pressure tester (diesel) - VAS 6551- to open ends of
fuel supply line -1- using suitable lines.
– Switch on pressure tester (diesel) - VAS 6551- by pressing
On/Off button.
– Open shut-off taps “A” and “B” of pressure tester and close
shut-off tap “C”.
– Read pressure shown by pressure tester (diesel) - VAS 6551- .
– Place pressure tester (diesel) - VAS 6551- onto windscreen
so that measured value can be read from inside vehicle.
– Increase idling speed to 2500 rpm. Read current pressure.
– If the delivery pressure temporarily drops, renew fuel delivery
unit ⇒ page 25 .
– If specifications are obtained, renew fuel filter to ensure the
fuel filter is not blocked.
– Check fuel pump delivery rate ⇒ page 43 .
8.1.3 Checking delivery rate of fuel system

pressurisation pump - G6- , engine co‐
des AXD, AXE, BLJ, BNZ, BPC

Test conditions
Procedure
– Connect suitable line from pressure tester (diesel) - VAS 6551-
to fuel supply line -1-.
– Place open end of line in the measuring tank.
– Bleed fuel system ⇒ Vehicle diagnostic tester.
Note
The fuel pump will be activated for 70 seconds.
– After 30 seconds, switch off ignition and read the amount of

fuel delivered in the measuring container. Specification: at
least 1000 ml/30 seconds.
If specification is not obtained
– Check voltage supply ⇒ page 45 and current draw
⇒ page 47 of fuel pump.
8.1.4 Checking delivery rate of fuel system

des CAAA, CAAB, CAAC, CAAD,
8. Fuel pump 43

Test conditions
Procedure
– Connect suitable line from pressure tester (diesel) - VAS 6551-
to fuel supply line -1-.
– Place open end of line in the measuring tank.
– Connect ⇒ Vehicle diagnostic tester and carry out Test elec-
tric fuel pump(s) .
Note
– When fuel stops flowing, read amount of fuel delivered as in‐

dicated on measuring container. Specified amount at least
1000 ml/30 sec.
– Check voltage supply ⇒ page 45 and current draw
⇒ page 48 of fuel pump.

8.1.5 Checking voltage supply of fuel system

Test conditions
• The battery voltage must be at least 12 V; if necessary connect
a battery charger.
Procedure
– Switch on ignition. The fuel pump must be heard to run for
about 2 seconds.
– Switch off ignition.
If the fuel pump does not start:
– Check fuel pump ⇒ Vehicle diagnostic tester.
8.1.6 Checking voltage supply of fuel system pressurisation pump - G6- , engine
codes CAAA, CAAB, CAAC, CAAD, CAAE, CCHA, CCHB, CFCA

equipment required
8. Fuel pump 45
♦ Pick-up clamp - V.A.G 1526B/2-

♦ Hand multimeter - V.A.G 1526D-
♦ Test instrument adapter/DSO (5-pin) - VAS 5565-
Test conditions
a battery charger.
Procedure
– Pull out connector on supplementary fuel pump - V393- .
– Switch on ignition. The fuel pump must run audibly for about
2 seconds.
– Switch off ignition.
If the fuel pump does not start:
– Pull connector off fuel delivery unit flange.
Note
The fuel tank has to be lowered in order to be able to remove the

connector from the flange of the fuel pump unit ⇒ page 21
– Remove cover of fuel delivery unit.

– Connect test instrument adapter/DSO (5-pin) - VAS 5565- be‐
tween connector and flange.
– Connect hand-held multimeter - V.A.G 1526D- to contacts
-1- and -5- of adapter.
– Connect vehicle diagnostic tester , and perform function
“Check electric fuel pump”.
Note
– Read voltage value on hand-held multimeter - V.A.G 1526D- :

Specification = battery voltage.
If no voltage is present:
– Check activation of fuel pump relay and wiring for open circuit
and short circuit ⇒ Vehicle diagnostic tester.
Voltage supply OK:
– Check that the electrical lines between flange and fuel pump
are connected and have continuity.
If no open circuit can be found:
– Renew fuel delivery unit ⇒ page 25 .

8.1.7 Checking current draw of fuel system pressurisation pump - G6- , engine
codes AXD, AXE, BLJ, BNZ, BPC

equipment required
♦ Pick-up clamp - V.A.G 1526B/2-

Note
The battery voltage and the diesel fuel temperature have a great
influence on the current draw of the fuel pump. For this reason,
ensure that the battery voltage is at least 12 V whilst checking,
and that the diesel fuel temperature in the fuel tank does not fall
to nearly the freezing point.
Test conditions
• Diesel fuel temperature above 10°C
8. Fuel pump 47

a battery charger.
Procedure
Note


– Connect test instrument adapter/DSO (5-pin) - VAS 5565- to
connector and fuel delivery unit.
– Connect pick-up clamp -A- to red terminal with lettering “pick-
up clamp” for test instrument adapter/DSO (5-pin) - VAS
5565- .
Note
Pickup clamp of hand-held multimeter - V.A.G 1526 E- can also

be connected to red terminal with lettering “pickup clamp” of test
instrument adapter/DSO (5-pin) - VAS 5565- .
– Switch on ignition.
– Bleed fuel system ⇒ Vehicle diagnostic tester.
Note
– Read current draw on hand-held multimeter - V.A.G 1526 E- .

Specification: max. 7.5 amps.
– If the measured value is not within specifications:
8.1.8 Checking current draw of fuel system

des CAAA, CAAB, CAAC, CAAD,

Note
The battery voltage and the diesel fuel temperature have a great
influence on the current draw of the fuel pump. For this reason,
ensure that the battery voltage is at least 12 V whilst checking,
and that the diesel fuel temperature in the fuel tank does not fall
to nearly the freezing point.
Test conditions
• Diesel fuel temperature above 10°C
a battery charger.
Procedure
Note


8. Fuel pump 49
– Connect test instrument adapter/DSO (5-pin) - VAS 5565- to

connector and fuel delivery unit.
– Connect pick-up clamp -A- to red terminal with lettering “pick-
up clamp” for test instrument adapter/DSO (5-pin) - VAS
5565- .
Note
Pickup clamp of hand-held multimeter - V.A.G 1526 E- can also

be connected to red terminal with lettering “pickup clamp” of test
instrument adapter/DSO (5-pin) - VAS 5565- .
– Pull out connector on supplementary fuel pump - V393- .

– Switch on ignition.
tric fuel pump(s) .
Note
– Read current draw on hand-held multimeter - V.A.G 1526 E- .

Specification: max. 7.5 amps.
– If the measured value is not within specifications:
8.2 Removing and installing tandem pump

⇒ “8.2.1 Removing and installing tandem pump, engine codes
AXB, AXC, BRR, BRS”, page 50
⇒ “8.2.2 Removing and installing tandem pump, engine codes
AXD, AXE, BLJ, BNZ, BPC”, page 53
8.2.1 Removing and installing tandem pump,

engine codes AXB, AXC, BRR, BRS

♦ Hose clamp pliers - VAS 6340-
Removing
DANGER!
The tandem pump may, under no circumstances, be disman‐

tled as the vacuum part could otherwise malfunction.
This would result in failure of the brake servo.
The fuel and the fuel lines in the fuel system can become very
hot (danger of scalding)!
Wear protective gloves.
Vehicles with fuel preheating

– Pull supply hose (white marking) and return hose (blue mark‐
ing) off fuel filter.
– Connect diesel extractor - VAS 5226- to return hose.
– Operate diesel extractor - VAS 5226- until no more fuel comes
out of return hose.
Vehicles without fuel preheating
– Pull supply hose off fuel filter.
– Separate return hose connection (blue marking)/return line
(brown) next to fuel filter.
out of return hose.
– Remove coolant expansion tank and place to one side (leaving
hoses connected).
8. Fuel pump 51
– Remove charge air pipe between intake manifold and charge

air cooler.
– Detach vacuum line -1- of brake servo from tandem pump
-4-.
– Detach fuel supply line -2- from tandem pump -4-.
– Remove tandem pump -4- from cylinder head.
– Pull tandem pump upwards slightly and remove fuel line -3-
from tandem pump -4-.
Installing
note the following:
Note
♦ Ensure that tandem pump coupling seats properly in shaft.

♦ Always renew tandem pump seals.
– Install tandem pump and tighten upper securing bolts.

– Tighten lower securing bolts .
– Connect return hose (blue or blue marking) -3- and vacuum

line -1- to tandem pump.
– Connect supply hose (black) to supply connection -2- and
brake servo vacuum line -1- to tandem pump -4-.
Vehicles with fuel preheating
– Connect supply hose ⇒ Item 10 (page 34) and return hose
⇒ Item 11 (page 34) to fuel filter.
Vehicles without fuel preheating
– Pull supply hose ⇒ Item 1 (page 36) off fuel filter.
– Connect return hose to return line.
– Install charge air pipe between intake manifold and charge air
cooler.
– Secure coolant expansion tank.
Note
The tandem pump must always be checked for internal leaks be‐
tween fuel side and oil side after reinstalling a used tandem pump
⇒ page 59 .
– Bleeding fuel system ⇒ Maintenance ; Booklet 19.1 .

– Carry out road test and read all event memories ⇒ Vehicle
diagnostic tester.
Specified torques
♦ Bolts securing tandem pump to cylinder head ⇒ Rep. gr. 15 ;
Cylinder head; Assembly overview - cylinder head

8.2.2 Removing and installing tandem pump,

engine codes AXD, AXE, BLJ, BNZ,
BPC
Removing
DANGER!
The tandem pump may, under no circumstances, be disman‐

tled as the vacuum part could otherwise malfunction.
This would result in failure of the brake servo.

♦ Hose clamp pliers - VAS 6340-
– Remove coolant expansion tank and place to one side (leaving

hoses connected).
– Remove charge air pipe between intake manifold and charge
air cooler.
8. Fuel pump 53
– Detach vacuum line -1- of brake servo from tandem pump

-4-.
– Detach fuel line -2- from tandem pump -4-.
– Unscrew fuel line -3- from tandem pump -4-.
– Remove tandem pump -4- from cylinder head.
Installing
note the following:
Note
♦ Ensure that tandem pump coupling seats properly in shaft.

♦ Always renew tandem pump seals.
– Install tandem pump and tighten securing bolts -arrows-.

– Carry out leakage test ⇒ page 60 .
– Attach fuel hose -2- and vacuum hose -1- to tandem pump.
– Connect fuel line -3- to tandem pump -4-, and tighten union
nut to specified torque.
Note
On vehicles with no fuel pre-heating, separate return hose con‐

nection (blue marking)/return line (brown) next to fuel filter. Then,
connect diesel extractor - VAS 5226- to return hose.

out of return hose.
– Reconnect return hose (blue marking).
– Install charge air pipe between intake manifold and charge air
cooler.
– Secure coolant expansion tank.
Note
The tandem pump must always be checked for internal leaks be‐
tween fuel side and oil side after reinstalling a used tandem pump
⇒ page 60 .
– Carry out a road test, and read event memory ⇒ Vehicle di‐
agnostic tester; clear event memory of engine control unit.
Specified torques
♦ Bolts securing tandem pump to cylinder head ⇒ Rep. gr. 15 ;
Cylinder head; Assembly overview - cylinder head
Union nut for securing fuel line 25 Nm
to tandem pump

8.3 Checking tandem pump

⇒ “8.3.1 Checking delivery pressure of tandem pump, engine co‐
des AXB, AXC, BRR, BRS”, page 55
⇒ “8.3.2 Checking delivery pressure of tandem pump, engine co‐
des AXD, AXE, BLJ, BNZ, BPC”, page 57
⇒ “8.3.3 Checking for leaks (internal), engine codes AXB, AXC,
BRR, BRS”, page 59
⇒ “8.3.4 Checking for leaks (internal), engine codes AXD, AXE,
⇒ “8.3.5 Checking holding pressure, engine codes AXD, AXE,
8.3.1 Checking delivery pressure of tandem

pump, engine codes AXB, AXC, BRR,
BRS
♦ Tandem pump tester - VAS 5187- with adapter - VAS 5187/7-

Test conditions
• Coolant temperature must be at least 85°C.
• Unit injectors OK.
8. Fuel pump 55
Procedure
WARNING
The fuel and the fuel lines in the fuel system can become very
hot (danger of scalding)!
Wear protective gloves.
– Unscrew plug -arrow-.

– Connect tandem pump tester - VAS 5187- with adapter - VAS

5187/7- as shown.
– Connect ⇒ Vehicle diagnostic tester.
– Select Read measured value block in Engine electron-
ics .
– Read off idling speed in ⇒ Vehicle diagnostic tester.

– Increase speed to 4000 rpm.
– Check displayed pressure on pressure gauge.
Specification: at least 7.5 bar
– Using a hose clamp, clamp off return line between fuel filter
and tandem pump.
If specification is now obtained:
Pressure loss at unit injectors.
– Renew O-rings for unit injectors ⇒ Rep. gr. 23 ; Injectors/fuel
rail .
– Renew tandem pump ⇒ page 50 .
Note
After removing pressure gauge, tighten sealing. Always renew

seal.
Specified torques
Plug in tandem pump 25 Nm
8.3.2 Checking delivery pressure of tandem

pump, engine codes AXD, AXE, BLJ,
BNZ, BPC
8. Fuel pump 57
♦ Tandem pump tester - VAS 5187-

Test conditions

– Connect tandem pump tester - VAS 5187- as shown.

– Read measured value block with ⇒ Vehicle diagnostic tester.
– Read idling speed indicated in display zone 1 ⇒ Vehicle diag‐
nostic tester.
– Check displayed pressure on pressure gauge. Specification:
at least 7.5 bar
– Renew tandem pump ⇒ page 53 .
Note
♦ After removing pressure gauge, tighten plug to specified tor‐

que.
♦ Always renew plug with seal.
Specified torques
Plug in tandem pump 25 Nm
8.3.3 Checking for leaks (internal), engine co‐

des AXB, AXC, BRR, BRS
♦ Charge air system tester - V.A.G 1687-
Note
If a used tandem pump is reinstalled (e.g. after replacing or re‐

pairing a cylinder head and/or when installing a "short" engine), it
needs to be checked for internal leaks between fuel side and oil
side. In the event of a leak, it is possible for the fuel to mix with
the oil which may cause engine damage.
Procedure
– Detach fuel supply hose (white marking) and fuel return hose
(blue marking) from tandem pump.
– Seal fuel return connection on tandem pump with blind plug.
Secure blind plug with spring-type clip.
8. Fuel pump 59
Prepare charge air system tester - V.A.G 1687- as follows:

– Unscrew pressure control valve -2- completely and close
valves -3- and -4-.
– Connect test connection -5- to fuel supply connection of tan‐
dem pump using commercially available compressed air con‐
nection and a section of fuel hose. Secure by means of spring-
type clip.
Note
To turn the pressure regulating valve -2- the knob must be pulled
upwards.
– Connect compressed air hose -1- (compressed air supply) to

charge air system tester - V.A.G 1687- .
Note
If water is in inspection glass, drain via drain screw -6-.
– Open valve -3-.

– Adjust pressure to 1.0 bar with pressure control valve -2-.
Caution
The maximum test pressure of 1.3 bar must not be exceeded.
– Open valve -4- and wait until test circuit is full. If necessary,
readjust pressure to 1.0 bar.
– Close valve -3- to maintain pressure and observe pressure
drop over a period of 1 minute.
If the pressure does not drop the tandem pump can be reused, if
the pressure drops the tandem pump must be renewed.
8.3.4 Checking for leaks (internal), engine co‐

♦ Charge air system tester - V.A.G 1687-

Note
♦ If a used tandem pump is reinstalled (e.g. after replacing or

repairing a cylinder head and/or when installing a "short" en‐
gine), it needs to be checked for internal leaks between fuel
side and oil side. In the event of a leak, it is possible for the
fuel to mix with the oil which may cause engine damage.
♦ A union with union nut may be installed on supply hose of tan‐
dem pump.
♦ If necessary, use adapter from K-Jetronic pressure tester -
V.A.G 1318- .
Procedure
– Detach fuel supply hose (white marking) and fuel return hose
(blue marking) from tandem pump.
– Seal fuel return connection on tandem pump with blind plug.
Secure blind plug with spring-type clip.
Prepare charge air system tester - V.A.G 1687- as follows:
– Unscrew pressure control valve -2- completely and close
valves -3- and -4-.
– Seal tester union -5- using commercially available com‐
pressed air connection. Connect a section of fuel supply hose
to fuel supply union of tandem pump. Secure by means of
spring-type clip.
Note
To turn the pressure regulating valve -2- the knob must be pulled
upwards.
– Connect compressed air hose -1- (compressed air supply) to

charge air system tester - V.A.G 1687- .
Note
If water is in inspection glass, drain via drain screw -6-.
– Open valve -3-.

– Adjust pressure to 1.0 bar with pressure control valve -2-.
Caution
The maximum test pressure of 1.3 bar must not be exceeded.
– Open valve -4- and wait until test circuit is full. If necessary,
readjust pressure to 1.0 bar.
– Close valve -3- to maintain pressure and observe pressure
drop over a period of 1 minute.
If the pressure does not drop the tandem pump can be reused, if
the pressure drops the tandem pump must be renewed.
8. Fuel pump 61
8.3.5 Checking holding pressure, engine co‐

♦ Tandem pump tester - VAS 5187-
♦ Hose clamps to 25 mm - 3094-

Test conditions
• Fuel filter and fuel lines must not be blocked or damaged.
Procedure
– Unbolt coolant expansion tank, and secure it using cable tie,
for example.
– Thoroughly clean plug and surrounding areas before discon‐
necting.

Note
♦ Under no circumstances may dirt enter the hole of the tandem

pump.
♦ Ensure that no diesel fuel comes into contact with the coolant
hoses. If necessary, clean hoses immediately.
♦ Observe relevant disposal regulations.
♦ Do not forget the seals for the tandem pump tester - VAS
5187- .
8. Fuel pump 63
– Connect tandem pump tester - VAS 5187- as shown.

– Read measured value block with ⇒ Vehicle diagnostic tester.
– Read idling speed indicated in display zone 1 ⇒ Vehicle diag‐
nostic tester.
Note
If necessary, seek assistance from a second person to clamp off

fuel return hoses.
– Clamp off fuel hose to master cylinder with hose clamps up to

25 mm - 3094- .
– Clamp off fuel supply hose (white marking) to tandem pump
with hose clamps up to 25 mm - 3094- . Switch off engine.
– Switch off ignition and disconnect ⇒ Vehicle diagnostic tester.
– Read off displayed pressure on pressure gauge after approx.
30 minutes.
Specification: approx. 3.0 bar
– Read off pressure again after approx. 60 minutes:
Specification: approx. 2.5 bar
If the specified value is not reached, there is a leak.
Perform further checks as follows:
♦ Connections of fuel supply line
♦ Connections of fuel return line
♦ Fuel hoses
♦ Shaft seals on tandem pump ⇒ page 60
♦ Seals on unit injector ⇒ Rep. gr. 23 ; Injectors/fuel rail
♦ Within cylinder head
Note
♦ Ensure that no diesel fuel comes into contact with the coolant
hoses. If necessary, clean hoses immediately.
♦ Observe relevant disposal regulations.
♦ Always renew plug with seal.
– Remove tandem pump tester - VAS 5187- .

– Screw in new plug -arrow- finger-tight, then tighten it to speci‐

fied torque.
Specified torques
Plug 25 Nm
8.4 Supplementary fuel pump - V393-

⇒ “8.4.1 Assembly overview - supplementary fuel pump V393 ”,
page 65
⇒ “8.4.2 Removing and installing supplementary fuel pump V393
”, page 67
⇒ “8.4.3 Checking supplementary fuel pump V393 ”, page 68
8.4.1 Assembly overview - supplementary fuel pump - V393-

To prevent the high-pressure pump from running while it is empty
and to ensure that the engine starts quickly after parts have been
renewed, it is important to observe the following:
♦ If components of fuel system between fuel tank and high-pres‐
sure pump are unbolted, removed or renewed, “Bleeding fuel
system” function must be carried out to bleed fuel system us‐
ing ⇒ Vehicle diagnostic tester.
♦ This process takes 130 seconds. Fuel pumps are actuated a
total of 3 times in the process. The process must not be ter‐
minated prematurely.
8. Fuel pump 65
1 - Electrical connector
2 - Rubber mounting
3 - Supplementary fuel pump -
V393-
⇒ page 67
4 - Spring-type clip
5 - Supply line
❑ To supplementary fuel
pump - V393-
❑ Clip onto fuel filter with
identification -VM-
❑ black
6 - Return line
❑ From supplementary
fuel pump - V393-
❑ Secure in retainer
⇒ Item 10 (page 67) .
identification -RF-
❑ Blue marking
7 - Return line
❑ To fuel tank
identification -RT-
❑ Blue marking
8 - Supply line
❑ From fuel tank
❑ Clip onto fuel filter with identification -VF-
❑ black
9 - Fuel filter
❑ Ensure that filter is installed in correct position in holder as shown in illustration
❑ Without water drain plug
❑ Draining water from fuel filter is no longer possible
Note
To guarantee immediate engine

starting after renewing fuel filter, the
fuel system must be bled ⇒ Vehicle
diagnostic tester
❑ Removing and installing ⇒ Maintenance ; Booklet 19

10 - Bracket
❑ For return line ⇒ Item 6 (page 66)
❑ Secured to retainer ⇒ Item 11 (page 67) and supply line ⇒ Item 5 (page 66)
11 - Bracket
❑ For fuel filter
12 - Nut
❑ 10 Nm
13 - Bolt
❑ 20 Nm
14 - Bolt
❑ 10 Nm
15 - Clip
❑ For return line of power-assisted steering system
16 - Bracket
❑ For supplementary fuel pump - V393-
17 - Supply line
❑ From supplementary fuel pump - V393- to engine
18 - Cable bracket
❑ Secured to bracket ⇒ Item 16 (page 67)
8.4.2 Removing and installing supplementary

fuel pump - V393-
Removing
Observe rules for cleanliness ⇒ page 5 .
– Release connector -1- and pull off.
– Pull wiring harness -3- out of expansion tank -2-.
– Unscrew bolts -4- from expansion tank -2-, and place expan‐
sion tank to one side.
8. Fuel pump 67
– Detach fuel line -1- and -3- from the holder -2-.
– Remove bracket -2-.
– Collect escaping fuel with cleaning cloths.
– Remove clip -4- and pull fuel line -3- off the supplementary fuel
pump - V393- .
– Release connector -5- and pull off.

– Detach connector of wiring harness -3- from bracket.
– Detach wiring harness -3- from clip -4-.
– Remove nuts -2- (qty. 2) and bracket -1-.
– Collect escaping fuel with cleaning cloths.
– Open clip -2- and pull fuel line -1- off the bottom of supple‐
mentary fuel pump - V393- -3-.
Installing
Install in reverse order of removal. Observe the following when
doing this:
To prevent the high-pressure pump from running while it is empty
and to ensure that the engine starts quickly after parts have been
renewed, it is important to observe the following:
♦ If components of fuel system between fuel tank and high-pres‐
sure pump are unbolted, removed or renewed, “Bleeding fuel
system” function must be carried out to bleed fuel system us‐
ing ⇒ Vehicle diagnostic tester.
♦ This process takes 130 seconds. Fuel pumps are actuated a
total of 3 times in the process. The process must not be ter‐
minated prematurely.
Specified torques
♦ ⇒ “8.4.1 Assembly overview - supplementary fuel pump V393
”, page 65
8.4.3 Checking supplementary fuel pump -

V393-
Volkswagen Technical Site: http://vwts.ru http://vwts.info

♦ K-Jetronic pressure tester - V.A.G 1318-
Test conditions:
• Battery voltage at least 12.5 V.
• Fuel filter OK.
• Fuel tank: min. level »reserve«.
• Ignition switched off
Procedure
– Note safety precautions ⇒ page 4 .
– Wrap a clean cloth around the connection before opening the
fuel system. Then release pressure by carefully pulling hose
off connection.
– Pull fuel supply line -arrow- off high-pressure pump.
– Connect K-Jetronic pressure tester - V.A.G 1318- with suitable

adapter -2- to fuel supply line -1-. Connect other adapter -3-
from K-Jetronic pressure tester - V.A.G 1318- to open con‐
nection on high pressure pump.
8. Fuel pump 69
Note
The K-Jetronic pressure tester - V.A.G 1318- must be inserted as

an intermediate element into the fuel supply line.

tric fuel pump(s) .
Note
– Run fuel pumps until highest fuel pressure has built up.
• Specification: at least 3.5 bar
Check threaded connection between pressure gauge and fuel line
for leaks.
Check pressure tester for leaks.
Check fuel lines and their connections for leaks.
Check whether fuel filter is blocked.
Check fuel delivery rate of fuel system pressurisation pump - G6-
⇒ page 43 .
Note
Check fuel system for leaks.

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Service

Service Department. Technical Information

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.1 Engine number/engine data

Codes AXB AXC BRR BRS

Codes AXD AXE BLJ BNZ BPC

Codes AXD AXE BLJ BNZ BPC

Vehicles with four digit engine codes

Codes CCHA CCHB CFCA CAAD

2 Rep. gr.00 - Technical data

Codes CCHA CCHB CFCA CAAD

Volkswagen Technical Site: http://vwts.ru http://vwts.info

2.1 Safety regulations for working on fuel

When performing any repair work, especially in the engine

The fuel line is under pressure.

When removing and installing fuel gauge sender or fuel pump

4 Rep. gr.00 - Technical data

3.1 Rules for cleanliness

3.2 General information

3.2.1 General notes on fuel supply system

♦ Hose connections are secured with either spring-type or

3.2.2 General notes on fuel system

6 Rep. gr.00 - Technical data

ions. All other components must always be removed and

20 – Fuel supply system

1.1 Procedure should vehicle be misfueled

♦ Misfuelling can cause irreversible damage to the high-pres‐

These instructions are intended as a guide through the individual

8 Rep. gr.20 - Fuel supply system

⇒ “1.1.1 Step 1, engine was started with incorrect fuel”,

1.1.1 Step 1, engine was started with incorrect

1.1.2 Step 2, engine was not started with in‐

1. Procedure should vehicle be misfueled 9

– Renew fuel filter ⇒ page 33 .

1.1.3 Step 3, swarf in fuel delivery unit - GX1-

10 Rep. gr.20 - Fuel supply system

1.1.4 Step 4, no swarf in fuel delivery unit -

1.1.5 Step 5, there are metal particles in high-

1.1.6 Step 6, there are no metal particles in

1. Procedure should vehicle be misfueled 11

– Carry out road test.

12 Rep. gr.20 - Fuel supply system

2.1 Assembly overview - fuel tank

❑ Removing and installing

14 Rep. gr.20 - Fuel supply system

Non-return valve -arrow- in filler neck

Installation position of fuel gauge sender - G-

After installing the fuel gauge sender - G- , check whether fuel

❑ Removing and installing

16 Rep. gr.20 - Fuel supply system

Non-return valve -arrow- in filler neck

Installation position of fuel gauge sender - G-

After installing fuel gauge sender - G- , check whether fuel supply

2.2 Removing and installing fuel tank

2.2.1 Removing and installing fuel tank, en‐

Risk of explosion of fuel tank. If a new or completely empty fuel

Special tools and workshop

♦ Key for union nut - 3217-

18 Rep. gr.20 - Fuel supply system