VW Polo 5 2014 Fuel System Petrol Engines Eng

Service
Workshop Manual
Polo 2014 ➤
Polo Lim RUS 2016 ➤
Fuel supply system, petrol engines
Engine ID
CHY CHY CJZC CJZD CWV CZE DAJA DAJB CHZ
A B B A B
CHZ CWV CZC
C A A
Edition 08.2018
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.
Polo 2014 ➤ , Polo Lim RUS 2016 ➤
Fuel supply system, petrol engines - Edition 08.2018
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety regulations for working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety precautions when using testers and measuring instruments during a road test . . . . 1
1.3 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 2
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Rules for cleanliness when working on auxiliary/supplementary heater and fuel system . . 4
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2 Fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.1 Assembly overview - fuel delivery unit/fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.2 Removing and installing fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . 30
2.3 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3 Plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.1 Separating plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.1 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.2 Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.1 Assembly overview - activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.2 Removing and installing activated charcoal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.3 Checking fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6 Accelerator pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.1 Assembly overview - accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7 Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7.1 Checking fuel system pressurisation pump G6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Contents i
ii Contents
00 – Technical data
1 Safety information
(VRL012072; Edition 08.2018)
⇒ “1.1 Safety regulations for working on fuel supply”, page 1
⇒ “1.2 Safety precautions when using testers and measuring in‐
struments during a road test”, page 1
⇒ “1.3 Safety measures when working on vehicles with a start/
stop system”, page 2
1.1 Safety regulations for working on fuel supply

Risk of injury from highly pressurised fuel.
The fuel system is pressurised. Injury from fuel spray possible.
Before opening the fuel system:
– Wear protective goggles.
– Wear protective gloves.
– To release pressure, wrap a clean cloth around the connection
and carefully loosen the connection.
Danger of fire caused by escaping fuel

When the battery is connected and the driver door opens, the door
contact switch activates the fuel pump. Escaping fuel can ignite
and cause a fire.
– Disconnect voltage supply to fuel pump before opening the
fuel system.
CAUTION
The fuel system is pressurised.
Danger of injury caused by fuel spray.
– To release pressure, wrap a clean cloth around the connec‐
tion and carefully loosen the connection.
1.2 Safety precautions when using testers and measuring instruments during
a road test
Risk of injury caused by unsecured testing and measuring instru‐
ments
When the front passenger airbag is triggered in an accident, in‐
sufficiently secured testing and measuring instruments become
dangerous projectiles.
– Secure testing and measuring instruments on the rear seat.
or
1. Safety information 1
– Have a second person operate the test and measuring equip‐

ment on the rear seat.
1.3 Safety measures when working on vehicles with a start/stop system

Risk of injury due to unexpected motor start
If the vehicle’s start/stop system is activated, the engine can start
unexpectedly. A message in the dash panel insert indicates
whether the start/stop system is activated.
– Deactivate start/stop system by switching off the ignition.
2 Rep. gr.00 - Technical data

2 Identification
⇒ “2.1 Engine number/engine data”, page 3
2.1 Engine number/engine data

Codes CHY CHY CJZ CJZ CZE CWV CWV DA‐ DAJB CHZ CHZC CZCA
A B D C A A B JA B
Exhaust emis‐ EU 6 EU 6 EU 6 EU 6 EU 6 EU 6 EU 6 EU 6 EU 6 EU 6 EU 6 EU 6
sion standard
Dis‐ l 1.0 1.0 1.2 1.2 1.4 1.6 1.6 1.8 1.8 1.0 1.0 1.4
place‐
ment
Power kW 44 55 81 66 110 81 66 141 141 70 81 92
RON 95 95 95 95 95 95 un‐ 95 un‐ 95 95 un‐ 95 95 un‐ 95 un‐
un‐ un‐ un‐ un‐ un‐ lea‐ lea‐ un‐ lea‐ un‐ lea‐ lea‐
lea‐ lea‐ lea‐ lea‐ lea‐ ded1 ded1 lea‐ ded1 lea‐ ded1 ded1
ded1 ded1 ded1 ded1 ded1 ded1 ded1
1)In exceptional circumstances min. 91 RON, however with re‐
duced performance.
Volkswagen Technical Site: http://vwts.ru http://vwts.info
2. Identification 3
3 General information
⇒ “3.1 Rules for cleanliness when working on auxiliary/supple‐
mentary heater and fuel system”, page 4
3.1 Rules for cleanliness when working on

auxiliary/supplementary heater and fuel
system
When working on the fuel supply and injection system, pay careful
attention to the following “rules”:
♦ 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).
♦ When the system is open: Do not work with compressed air.
♦ Do not move the vehicle.
♦ Immediately seal open lines and unions with clean plugs, for
example from engine bung set - VAS 6122- .
♦ Protect disconnected electrical connectors from dirt and water,
and reconnect them only when dry.
♦ To extract E 85 fuel, use only fuel extractor - VAS 5190 A- .
4 Rep. gr.00 - Technical data

20 – Fuel supply system

1 Fuel
⇒ “1.1 Assembly overview - fuel tank”, page 5
⇒ “1.3 Removing and installing fuel tank”, page 17
⇒ “1.2 Emptying fuel tank”, page 10
1.1 Assembly overview - fuel tank

⇒ “1.1.1 Assembly overview - fuel tank, hatchback”, page 5
⇒ “1.1.2 Assembly overview - fuel tank, saloon”, page 7
1.1.1 Assembly overview - fuel tank, hatchback
1 - Fastener
2 - Cap
3 - Seal
❑ Renew if damaged
4 - Securing bolt
5 - Tank flap unit
❑ With rubber cup.
❑ Removing and installing
⇒ General body repairs,
exterior; Rep. gr. 55 ;
Tank flap unit; Remov‐
ing and installing fuel
tank flap unit .
6 - Gravity valve
❑ To remove valve unclip
upwards out of support.
❑ Check valve for
through-flow.
❑ Valve vertical: open.
❑ Valve tilted 45°: closed.
7 - Earth connection
❑ Ensure firm seating
8 - Breather line
9 - Activated charcoal filter
❑ Location: in rear right
wheel housing.
10 - Bolt
❑ 10 Nm
11 - Breather line
❑ Clipped onto fuel tank
12 - Bolt
❑ 25 Nm
1. Fuel 5
13 - Fuel
❑ When removing, support using engine and gearbox jack - V.A.G 1383 A- .
❑ Removing and installing ⇒ page 17
14 - Securing strap
15 - Breather line
16 - Fuel filter
❑ With pressure limiting valve
❑ Installation position: arrow indicates direction of flow.
❑ Observe pressure values on pressure regulator
17 - Supply line
❑ black
❑ To fuel rail
18 - Bolt
❑ For fuel filter clamp
❑ 5 Nm
19 - Seal
❑ When installing, fit dry in fuel tank opening.
❑ Moisten with fuel only when installing flange.
20 - Fuel gauge sender - G-
❑ Adjusting ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
21 - Fuel delivery unit
❑ Assembly overview - ⇒ page 27
❑ Clean strainer if soiled
❑ Checking fuel pump ⇒ page 58 .
❑ Note installation position on fuel tank ⇒ page 7
22 - Return line
❑ blue
❑ Clipped onto side of fuel tank.
23 - Supply line
❑ black
❑ Clipped onto side of fuel tank.
24 - Locking ring
❑ Observe various types ⇒ page 27
25 - Bolt
❑ 10 Nm
26 - Bleeder valve
❑ Checking ⇒ page 7
❑ To remove press locking latch lightly -arrow- and pull valve out.
6 Rep. gr.20 - Fuel supply system

Installation position of fuel delivery unit

Note installation position of fuel delivery unit flange: mark on
flange -2- must align with mark on fuel tank -1-.
Return line -1- (blue or with blue marking) is connected to the
connection marked -R-.
Supply line -2- (black) is connected to the connection marked
-V-.
Checking breather valve

If the lever is in rest position, the breather valve is closed.
If the lever is operated in direction of arrow, the breather valve is
open.
Note
Before installing breather valve remove fuel tank cap.
Earth connection for fuel filler neck

– Connect earth connection as shown in illustration.
– Ensure that connector -2- for earth connection is properly
seated on metal ring -1- of fuel filler neck.
– First, hook contact tab -3- of earth connection in mounting hole
on fuel tank -5-.
– Then, press in spacer bush -4-.
– After installation, check electrical connection using an Ohm‐
meter.
– Check connection of metal ring on fuel filler neck by measuring
between ring and a bare metal part of the body.
Specification: approx. 0 ohm.
1.1.2 Assembly overview - fuel tank, saloon
1. Fuel 7
1 - Return line
❑ blue
❑ Clipped onto side of fuel
tank.
2 - Supply line
❑ black
❑ To fuel rail
3 - Tank flap unit
❑ With rubber cup.
⇒ General body repairs,
exterior; Rep. gr. 55 ;
Tank flap unit; Remov‐
ing and installing fuel
tank flap unit .
4 - Bolt
❑ 3 Nm
5 - Sealing device
6 - Hose
wheel housing.
❑ Assembly overview
⇒ page 49
8 - Ventilation and breather line
❑ Clipped onto fuel tank
9 - Fuel
❑ When removing, support using engine and gearbox jack - V.A.G 1383 A- .
10 - Bolt
❑ 25 Nm
❑ Qty. 5
11 - Heat shield
12 - Securing strap
13 - Supply line
❑ black
❑ To fuel rail
14 - Breather line
❑ white
❑ From activated charcoal filter system solenoid valve 1 - N80-
15 - Fuel filter
❑ With pressure regulator.

❑ Installation position: arrow indicates direction of flow.
16 - Seal
❑ When installing, fit dry in fuel tank opening.
❑ Removing and installing external fuel gauge sender - G- with 2 cable connections ⇒ page 40
❑ Removing and installing internal fuel gauge sender - G- ⇒ page 40 .
❑ Checking fuel pump ⇒ page 58 .
❑ Note installation position on fuel tank ⇒ page 9
19 - Union nut
❑ 80 Nm
❑ Remove and install using union nut tool - 3217-

Mark on sender -2- must align with mark on fuel tank -1-.
Return line on connection marked -R-.
Supply line on connection marked -V-
Note
After installing fuel delivery unit flange, check that supply, return
and breather lines are still clipped onto fuel tank.
Checking breather valve

Lever in rest position: closed
Lever pushed in -direction of arrow-: Open
Note
Before installing breather valve remove fuel tank cap.
1. Fuel 9
1.2 Emptying fuel tank

⇒ “1.2.1 Emptying fuel tank when fuel pump is intact”,
page 10
⇒ “1.2.2 Emptying fuel tank if it is more than 3/4 full”, page 13
⇒ “1.2.3 Emptying fuel tank if it is less than 3/4 full”, page 14
1.2.1 Emptying fuel tank when fuel pump is intact
Special tools and workshop

equipment required
♦ Removal wedge - 3409-

♦ Remote control - V.A.G 1348/3A-
♦ Test instrument adapter/DSO (5-pin) - VAS 5565-
♦ Fuel extractor - VAS 5190-
♦ Fuel extractor - VAS 5190 A- for E 85 fuel (not shown).
♦ Adapter for fuel extraction - VAS 5190-

Note
If the fuel extraction unit - VAS 5190- is still fitted with the extrac‐
tion hose with a solid tip, the extraction hose must be replaced
with the version with a screwed tip.
– Pull off supply line (metal connector) -1-. Separate plug-in

connectors ⇒ page 43 .
CAUTION
– Collect escaping fuel with a cleaning cloth.
– Connect fuel extractor - VAS 5190- with adapter for fuel ex‐
tractor - VAS 5190 /3- to fuel supply line.
– Secure earth wire of fuel extractor to a bare metal part of the
body.
– Fold up bench seat ⇒ General body repairs, interior; Rep. gr.
72 ; Rear seats; Removing and installing bench seat/individual
seats .
Vehicles with fuel pump control unit - J538- :

– Unclip fuel pump control unit - J538- -2- from cover -1-.
1. Fuel 11
Continued for all vehicles:

– Unclip cover -1- at retaining tabs -arrows- using removal
wedge - 3409- .
– Pull off connector -arrow-.
– Connect test instrument adapter/DSO (5-pin) - VAS 5565- to

connector and fuel delivery unit.
– Connect remote control - V.A.G 1348/3A- to test instrument
adapter/DSO (5-pin) - VAS 5565- and to battery positive (+).
Note
This step serves only to have the fuel pump running when the
engine is stopped.
– Open tank flap unit.

– Clean area around fuel filler neck.
– Unscrew cap from fuel filler neck -arrow-.
– Operate remote control - V.A.G 1348/3A- and shut-off tap on
fuel extractor - VAS 5190- until fuel tank is empty.
NOTICE
Risk of irreparable damage to fuel pump if allowed to run dry.
– Never allow fuel pump to run »dry«.

1.2.2 Emptying fuel tank if it is more than 3/4

full
Special tools and workshop equipment required

– Remove cone piece -2- from shaft -1- of fuel extractor -
VAS 5190- .
– Make a mark -arrow- at dimension -a- from end of extraction

hose of fuel extractor - VAS 5190- .
– Dimension -a- is 1180 mm.
– Use insulating tape for this.

Secure earth wire of fuel extractor to a bare metal part of the body.
1. Fuel 13
– Screw shaft -1- of fuel extractor - VAS 5190- onto fuel tank
filler neck.
– Push extraction hose of fuel extractor into fuel tank until pre‐
viously attached marking -arrow- on hose coincides with shaft
piece -2-.
Note
A ball valve -2- is located at the bottom of the filler neck in the fuel
tank -1-; take care not to damage it with the extraction hose -3-.
Therefore push hose into filler neck only as far as marking
-arrow-.
– Drain fuel tank via filler neck as far as possible.

– Pull extraction hose out carefully.
Note
♦ When no more fuel is extracted, the tank is emptied just

enough for the sender flange to be opened without danger.
♦ If work has to be done on fuel delivery unit or on fuel gauge
sender , proceed as follows ⇒ page 14 :
1.2.3 Emptying fuel tank if it is less than 3/4 full


equipment required
♦ Key for union nut - 3217-

♦ Torque wrench - V.A.G 1332-
♦ Special wrench - T10202-
1. Fuel 15
Note
Separate plug-in connectors ⇒ page 43 .

seats .

wedge - 3409- .
– Release connector -1- and pull off.

– Disconnect fuel lines -2- and -3- from fuel delivery unit. Sep‐
arate plug-in connectors ⇒ page 43 .
CAUTION

Vehicles with union nut:

– Open locking ring using union nut wrench - 3217- .
Vehicles with locking ring:

– Do not cant key - T10202- and press against locking ring firmly.
– Open locking ring using wrench - T10202- and raise flange
slightly.

– Raise cover -3- of fuel delivery unit.
Secure earth wire of fuel extractor to a bare metal part of the body.
– Insert suction hose of fuel extractor - VAS 5190- as far as
possible into fuel tank.
– Then extract fuel.
If the fuel tank needs only to be emptied, install fuel delivery unit
again ⇒ page 30 .
1.3 Removing and installing fuel tank

⇒ “1.3.1 Removing and installing fuel tank, hatchback”,
page 17
⇒ “1.3.2 Removing and installing fuel tank, saloon”, page 23
1.3.1 Removing and installing fuel tank,

hatchback
1. Fuel 17
♦ Engine and gearbox jack - V.A.G 1383 A-
Removing
– Move front seats to foremost position.
– Switch off ignition.

– Fold rear seat bench up ⇒ General body repairs, interior; Rep.

gr. 72 ; Rear seat; Removing and installing bench seat / indi‐
vidual seats .

wedge - 3409- .

– Drain fuel tank ⇒ page 10 .
1. Fuel 19

Note
In order to prevent the ingress of dirt, seal the opening of the fuel
filler neck with a clean plug.
– Remove tank flap unit -2- ⇒ General body repairs, exterior;

Rep. gr. 55 ; Tank flap unit; Removing and installing tank flap
unit .
– Remove rear right wheel ⇒ Running gear, axles, steering;
Rep. gr. 44 ; Wheels, tyres and alignment .
– Remove rear right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liner; Assembly
overview - rear wheel housing liner .
– Remove activated charcoal filter ⇒ page 50 .
Vehicles with drum brake on rear axle:
– Disengage handbrake cables from handbrake lever ⇒ Brake
system; Rep. gr. 46 ; Parking brake; Removing and installing
rear brake cable .
Vehicles with disc brake on rear axle:
– Disengage handbrake cables from brake calipers ⇒ Brake
system; Rep. gr. 46 ; Parking brake; Removing and installing
rear brake cable .
– Remove rear axle ⇒ Running gear, axles, steering; Rep. gr.
42 ; Rear axle; Removing and installing rear axle .
– Remove front silencer together with rear silencer ⇒ Rep. gr.
26 ; Exhaust pipes/silencers; Assembly overview – silencers .
– Disconnect supply line -1- and breather line -2- at connecting

point. Separate plug-in connectors ⇒ page 43 .
CAUTION

– Unscrew bolts -arrows- on filler neck.
– Unscrew bolts -3- and -5- on fuel tank -1-.

– Remove securing strap -7-.
– Support fuel tank with engine and gearbox jack - V.A.G 1383/
A- .
1. Fuel 21
– Unscrew bolts -2-; -4- and -6-.
Note
♦ For reasons of clarity, the fuel tank -1- is shown without engine
and gearbox jack - V.A.G 1383 A- .
♦ The aid of a 2nd mechanic is required to remove the fuel tank
-1-.
– Lower fuel tank -1- using engine and gearbox jack - V.A.G
1383 A- .
– Additionally support fuel tank -1- by hand while doing so.
Installing
WARNING
Risk of explosion of fuel tank caused by fuel pump activation.
Risk of severe injuries and burns.
– If a new or completely empty fuel tank has been installed, fill
it immediately with at least 5 litres of fuel.
Install in reverse order of removal. The following should be ob‐

served:
Note
Separate plug-in connectors ⇒ page 43 .
– If fitted, check that metering pump - V54- is firmly seated.

– Install breather lines and fuel lines free of kinks.
– Ensure that the filler neck of the fuel tank is correctly inserted
into the opening in the body.
– Position the fuel tank together with securing strap on under‐
body, using engine and gearbox jack - V.A.G 1383 A- .
– Note position of securing strap.
– After installing fuel tank, check that the supply, return and
breather lines are still clipped onto the fuel tank.
– Ensure that bracket for exhaust system is seated correctly ⇒
Rep. gr. 26 ; Exhaust pipes/silencers; Assembly overview -
silencers .
– Ensure that line connections are tight.
– Ensure connections are secured properly by pulling.
– Note installation position of earth connection ⇒ page 7 .

– Note installation position of cover.

Torque settings
♦ ⇒ “1.1 Assembly overview - fuel tank”, page 5
♦ ⇒ “5.1 Assembly overview - activated charcoal filter system”,
page 49
♦ ⇒ General body repairs, interior; Rep. gr. 72 ; Rear seat;
Removing and installing bench seat / individual seats
♦ ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Assembly overview
- silencers
♦ ⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit;
Removing and installing tank flap unit
♦ ⇒ Running gear, axles, steering; Rep. gr. 42 ; Rear axle;
Removing and installing rear axle .
♦ ⇒ Brake system; Rep. gr. 46 ; Rear brake; Assembly overview
- rear brake
♦ ⇒ Running gear, axles, steering; Rep. gr. 44 ; Wheels, tyres;
Wheel change
1.3.2 Removing and installing fuel tank, sa‐

loon
♦ Torque wrench (5 … 50 Nm) - V.A.G 1331-
♦ Engine and gearbox jack - V.A.G 1383 A-
1. Fuel 23
Removing
– Unscrew tank flap unit securing bolt and remove tank flap unit
⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit .
– Fold rear bench seat forwards.
– Remove clip -arrow- on both sides of vehicle and raise trim
-1- or remove if necessary ⇒ General body repairs, interior;
Rep. gr. 70 ; Interior trim .
– Fold floor covering -2- as far forward as possible.
Vehicles with bolt-on cover:

– Remove cover -1- from fuel delivery unit, unscrewing bolts
-arrows- to do so.
Vehicles with push-on cover:

– Unclip cover -1- for flange at retaining tabs -arrows-, using re‐
moval wedge - 3409- .

Continued for all vehicles

– Release connector -1- and pull it off flange -2-.
– Unbolt right rear wheel.
pairs, exterior; Rep. gr. 66 ; Wheel housing liner .
– Pull lines -arrows- off activated charcoal filter.
Note
Press in securing ring to release lines.
– Unscrew bolts -arrows- on filler neck.

– Detach all retainers for rear section of exhaust system ⇒ Rep.
gr. 26 ; Exhaust pipes and silencers; Assembly overview -
silencers .
– Then lower exhaust system slightly and attach to body with
suitable wire.
– Remove rear axle ⇒ Running gear, axles, steering; Rep. gr.
42 ; Rear axle; Removing and installing rear axle .
CAUTION
– Disconnect supply line -1- (black) and breather line -2- (white)
at connecting point.
Note
Press in securing ring to release the fuel lines.
1. Fuel 25
– Disconnect securing straps -1- and remove bolts -arrows-.
– Support fuel tank with engine and gearbox jack - V.A.G 1383
A- .
– Lower fuel tank using engine and gearbox jack - V.A.G 1383
A- .
Installing
Install in reverse order of removal. During this step, observe the
following:
♦ Install breather and fuel hoses free of kinks.
♦ Ensure fuel hoses are seated correctly.
♦ Check fuel tank/body earth connection on filler neck.
♦ Do not interchange supply line and return line (return line blue
or with blue marking, supply line black).
Note
After installing fuel tank, check that the supply, return and breath‐
er lines are still clipped onto the fuel tank.
– Fill 5 l of fuel.
WARNING
Torque settings
♦ ⇒ General body repairs, interior; Rep. gr. 72 ; Rear seat;
Removing and installing bench seat / individual seats
♦ ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Assembly overview
- silencers
♦ ⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit;
Removing and installing tank flap unit
♦ ⇒ Running gear, axles, steering; Rep. gr. 42 ; Rear axle;
Removing and installing rear axle .

2 Fuel delivery unit, fuel gauge sender

⇒ “2.1 Assembly overview - fuel delivery unit/fuel gauge sender”,
page 27
⇒ “2.2 Removing and installing fuel delivery unit, fuel gauge send‐
er”, page 30
⇒ “2.3 Removing and installing fuel gauge sender G ”,
page 40
2.1 Assembly overview - fuel delivery unit/

fuel gauge sender
⇒ “2.1.1 Assembly overview - fuel delivery unit and fuel gauge
sender, vehicles with union nut”, page 27
⇒ “2.1.2 Assembly overview - fuel delivery unit and fuel gauge
sender, vehicles with locking ring”, page 28
⇒ “2.1.3 Assembly overview - fuel delivery unit/fuel gauge sender,
vehicles with auxiliary heater”, page 29
2.1.1 Assembly overview - fuel delivery unit and fuel gauge sender, vehicles with
union nut

⇒ page 30
❑ Checking fuel pump
⇒ page 58 .
❑ Note installation posi‐
tion on fuel tank
⇒ page 28
2 - Seal
❑ When sealing flange is
inserted, ensure that
seal is not damaged or
squashed.
❑ Insert seal for fuel deliv‐
ery unit dry into opening
of fuel tank.
❑ Moisten seal with fuel
only when installing fuel
delivery unit.
3 - Locking ring
❑ 80 Nm
4 - Fuel supply line
❑ Ensure fuel hoses are
seated firmly.
❑ Do not interchange sup‐
ply and return lines.
❑ After installing fuel deliv‐
ery unit, check that the
line is still clipped onto
fuel tank.
❑ Ensure fuel hoses are
seated firmly.
2. Fuel delivery unit, fuel gauge sender 27

❑ Do not interchange supply and return lines.
❑ After installing fuel delivery unit, check that the line is still clipped onto fuel tank.
6 - Fuel pump control unit - J538-

Note installation position of fuel delivery unit flange: mark on
Return line -1- (blue or with blue marking) is connected to the
connection marked -R-.
Supply line -2- (black) is connected to the connection marked
-V-.
2.1.2 Assembly overview - fuel delivery unit and fuel gauge sender, vehicles with
locking ring
1 - Locking ring
❑ 110 Nm
2 - Supply line
❑ black
tank.
3 - Return line
❑ blue
tank.
4 - Flange
❑ For fuel delivery unit.
❑ Note installation posi‐
tion of flange on fuel
tank ⇒ page 29 .
⇒ page 40
⇒ page 30
❑ With fuel system pres‐
surisation pump - G6-
❑ Checking fuel pump
⇒ page 58 .
7 - Seal
❑ Renew
❑ When installing, fit dry in
fuel tank opening.

Installation position of flange

– Push flange downwards against spring force and move flange
into installation position.
• Tab -2- on flange must be between lugs -1- and -3- on fuel
tank.
• -Arrow- points in direction of travel.
2.1.3 Assembly overview - fuel delivery unit/fuel gauge sender, vehicles with
auxiliary heater

❑ With fuel system pres‐
surisation pump - G6-
❑ With integrated fuel fil‐
ter; fuel filter cannot be
renewed separately
❑ Carrying out electrical
test of fuel pump in Gui-
ded fault finding
mode ⇒ Vehicle diag‐
nostic tester
⇒ page 30
❑ After installing, fill vehi‐
cle with at least 5 litres
of fuel.
2 - Clip
❑ Renew after removal
❑ Secure hose connection
with the hose clips cor‐
responding to original
equipment.
3 - Clip
❑ Renew after removal
❑ Secure hose connection
with the hose clips cor‐
responding to original
equipment.
4 - Fuel line
❑ To metering pump -
V54-
⇒ page 34
5 - Sealing grommet
❑ Check for damage
6 - Fuel line
❑ To engine

2.2 Removing and installing fuel delivery

unit, fuel gauge sender
⇒ “2.2.1 Removing and installing fuel delivery unit/fuel gauge
sender, hatchback”, page 30
⇒ “2.2.2 Removing and installing fuel line for auxiliary/supple‐
mentary heater”, page 34
⇒ “2.2.3 Removing and installing fuel delivery unit/fuel gauge
sender, saloon”, page 36
2.2.1 Removing and installing fuel delivery

unit/fuel gauge sender, hatchback

Removing
seats .

wedge - 3409- .

CAUTION



slightly.


– Remove seal -1-.
– Place a cloth underneath to absorb fuel.
– Carefully pull out fuel delivery unit with fuel gauge sender - G-
through opening of fuel tank.
– Turn and tilt it as necessary while doing so.
Note
When removing the fuel delivery unit, ensure that the float arm of
the fuel gauge sender is not bent.
Note
♦ If delivery unit is to be renewed, old delivery unit must be

drained before disposal.
♦ Observe environmental regulations for disposal.
♦ Check fuel tank for foreign bodies and dirt.
Installing
– Install in reverse order of removal. The following should be
observed:
– When inserting fuel delivery unit, ensure that fuel gauge send‐
er is not bent.
– When flange is inserted, ensure that seal is not damaged or
squashed.
– Insert seal for fuel delivery unit dry into opening of fuel tank.
– Moisten seal with fuel only when installing fuel delivery unit.

– Note installation position of fuel delivery unit flange: mark on


– Push flange downwards against spring force and move flange
into installation position.
• Tab -2- on flange must be between lugs -1- and -3- on fuel
tank.
• -Arrow- points in direction of travel.
– Ensure fuel hoses are seated correctly.
– Do not interchange supply and return lines.
– After installing fuel delivery unit, check that the supply, return
and breather lines are still clipped onto the fuel tank.
– Check that connectors and lines are secured properly by pull‐
ing on them.
– Fill fuel tank with at least 5 litres of fuel.
WARNING
Torque settings
♦ ⇒ “2.1 Assembly overview - fuel delivery unit/fuel gauge send‐
er”, page 27
2.2.2 Removing and installing fuel line for aux‐

iliary/supplementary heater
Removing
– The fuel tank must not be more than 3/4 full. This ensures that
the fill level is below the flange of the fuel delivery unit.
– Remove rear bench seat ⇒ General body repairs, interior;
Rep. gr. 72 ; Rear seats; Removing and installing bench seat /
individual seats .
– Unclip cover -1- for flange at retaining tabs -arrows-, using re‐
moval wedge - 3409- .

– Unclip sealing grommet -1- downwards from cover -2-.

– Push cover -2- back along wiring harness -3-.
Vehicles with front-wheel drive:

– Release and pull off connector -1- on sealing flange.
– If fitted, detach connector -2- for metering pump - V54- of aux‐
iliary heater on sealing flange and lay connector aside.
Vehicles with all-wheel drive:

– Release and pull off connectors -1- and -2- on sealing flange.
– If fitted, detach connector -3- for metering pump - V54- of aux‐
iliary heater on sealing flange and lay connector aside.
If the fuel line for metering pump - V54- is to be disconnected from

fuel delivery unit:
– Open lower clip -3- on flange -1-.
CAUTION
– Do not open upper clip -4-.

– Pull fuel line -2- together with grommet off flange.
If a new fuel delivery unit is installed:
– Remove fuel line ⇒ page 35 .

– Remove fuel delivery unit ⇒ page 30 .

– The connection on the fuel delivery unit -2- must be opened.
– To do this, cut off sealing piece -3- on connection -1-.
– Cut it off on the respective marking line -arrow-.
– Deburr edges of cutting point.
– Prevent any dirt or swarf from entering the fuel delivery unit.
– Check fuel delivery unit for soiling, and clean it as necessary.
– Install fuel delivery unit ⇒ page 30 .
Installing fuel line:

– Insert fuel line -3- in connection -5-.
– Insert fuel line to stop -arrow-.
– While doing this, fit grommet -1- over connection.
– Renew lower clip -4-.
– If the fuel line or grommet has been renewed, the upper clip
must be renewed as well.
– Renew clips -2- and -4-, if they have been opened.
– Secure hose connections with the hose clips corresponding to
original equipment.
Torque settings
er”, page 27
2.2.3 Removing and installing fuel delivery

unit/fuel gauge sender, saloon

Removing
– Remove bench seat ⇒ General body repairs, interior; Rep. gr.
72 ; Rear seats; Removing and installing bench seat / individ‐
ual seats .
Limousine
– Remove clip -arrow- on both sides of vehicle and raise trim
-1- or remove if necessary ⇒ General body repairs, interior;
Rep. gr. 70 ; Interior trim .
– Fold floor covering -2- as far forward as possible.
Vehicles with bolt-on cover

– Remove cover -1- from fuel delivery unit, unscrewing bolts
-arrows- to do so.

– If present, bend sheet metal strips -arrows- downwards at

separating line.
Vehicles with push-on cover:

– If fitted, unclip fuel pump control unit - J538- -2- from cover
-1-.

wedge - 3409- .

CAUTION


– Remove seal -1-.
– Place a cloth underneath to absorb fuel.
– Carefully pull out fuel delivery unit with fuel gauge sender - G-
through opening of fuel tank.
– Turn and tilt it as necessary while doing so.
Note
When removing the fuel delivery unit, ensure that the float arm of
the fuel gauge sender is not bent.
Note
♦ If delivery unit is to be renewed, old delivery unit must be

drained before disposal.
♦ Observe environmental regulations for disposal.
♦ Check fuel tank for foreign bodies and dirt.
Installing
– Install in reverse order of removal. During this step, observe
the following:
– When inserting fuel delivery unit, ensure that fuel gauge send‐
er is not bent.
– When flange is inserted, ensure that seal is not damaged or
squashed.
– Insert seal for fuel delivery unit dry into opening of fuel tank.
– Moisten seal with fuel only when installing fuel delivery unit.

– Note installation position of fuel delivery unit flange: mark on

– Ensure fuel hoses are seated correctly.
– Do not interchange supply and return lines.
– After installing fuel delivery unit, check that the supply, return
and breather lines are still clipped onto the fuel tank.
– Check that connectors and lines are secured properly by pull‐
ing on them.
– Fill fuel tank with at least 5 litres of fuel.
WARNING
Torque settings
er”, page 27
2.3 Removing and installing fuel gauge

sender - G-
Removing
Note
♦ Note that the fuel gauge sender - G- is available in different

versions.
♦ After removing the fuel delivery unit, check which version of
fuel gauge sender - G- is fitted.

Version 1:
– Press fuel gauge sender - G- to one side slightly while pulling
upwards.

– If the sender cannot be released in this way, the securing tabs

-arrows- must also be pushed to the side slightly.
– Note colour assignment of cables for re-installation.

– Pull off electrical connectors -1- through -3-.
– Then bend back locking lugs of connectors.
Installing:
– Connect connectors -1- through -3-.
– When doing this, note the colour coding.
– Check connectors are secured properly by pulling.
– Insert fuel gauge sender - G- into guide on fuel delivery unit
and press down until it engages.
Version 2:
– Press together securing tabs -arrows- and remove fuel gauge
sender - G- upwards.
– Note colour assignment of cables for re-installation.
– Release connector lugs on lines -1-, -2- and -3- and discon‐
nect.
Installing
– Connect connectors -1- through -3-.
– When doing this, note the colour coding.
– Check connectors are secured properly by pulling.
– Insert fuel gauge sender - G- into guides on fuel delivery unit
and press down until it engages.
– Clip lines on corresponding positions and secure on cup into
retaining slots.

Version 3:
– Release connectors for lines -1- and -2- and pull them off.
– Raise securing tabs -3- and -4- using a screwdriver and pull
fuel gauge sender off downwards -arrow-.
Installing
Install in reverse order of removal. During this step, observe the
following:
– Insert fuel gauge sender - G- into guides on fuel delivery unit
and press upwards until it engages.
– Clamp connector in place and ensure engagement is secure.
– Install fuel delivery unit ⇒ page 30 .
Torque settings
er”, page 27

3 Plug-in connectors
⇒ “3.1 Separating plug-in connectors”, page 43
3.1 Separating plug-in connectors

♦ Lever - T10468-
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 43 .
♦ 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
CAUTION
3. Plug-in connectors 43
Version 1
Plug-in connector with release buttons -arrows- on right and left
Open
It is necessary to counterhold separating point for fuel -1- in en‐
gine compartment.
– Insert lever - T10468- between heat shield and stop -arrow- of
fuel line -2- and counterhold.
Continuation for all separating points of 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 43 .
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.
3. Plug-in connectors 45
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.

4 Fuel filter
⇒ “4.1 Assembly overview - fuel filter”, page 47
⇒ “4.2 Removing and installing fuel filter”, page 47
4.1 Assembly overview - fuel filter

If the fuel system does not have a return line, there is a pressure
limiting valve in the fuel filter. With this kind of system, only the
supply line is routed forwards into the engine compartment.
1 - Fuel filter
❑ With pressure limiting
valve
❑ Direction of flow is
marked with arrows
❑ Do not interchange con‐
nections
⇒ page 47
❑ Observe pressure val‐
ues on pressure regula‐
tor
❑ For allocation refer to ⇒
Electronic parts cata‐
logue (ETKA) .
❑ black
❑ From fuel tank
❑ Detach ⇒ page 43
3 - Fuel return line
❑ blue
❑ To fuel tank
4 - Fuel line
❑ black
❑ To engine
5 - Bolt
❑ 3 Nm
6 - Fuel filter holder
❑ Secured to fuel tank.
4.2 Removing and installing fuel filter

4. Fuel filter 47
♦ Drip tray, e.g. drip tray for workshop hoist - VAS 6208-
Removing
– Place tray under fuel filter.
CAUTION
– Pull off fuel lines -1-, -2- and -3-. Separate plug-in connectors
⇒ page 43 .
– Unscrew bolt -4-.
– Remove fuel filter.
Installing
Install in reverse order of removal. The following should be ob‐

served:
– Allocation of fuel filter ⇒ ETKA
– Direction of flow is indicated with an arrow on filter housing.
– Pin -2- on filter housing must engage in notch of guide -1- on
filter bracket.
Torque settings
♦ ⇒ “4.1 Assembly overview - fuel filter”, page 47

5 Activated charcoal filter system

⇒ “5.1 Assembly overview - activated charcoal filter system”, page
49
⇒ “5.2 Removing and installing activated charcoal filter”,
page 50
⇒ “5.3 Checking fuel tank breather”, page 52
5.1 Assembly overview - activated charcoal

filter system
⇒ “5.1.1 Assembly overview - activated charcoal filter, hatch‐
back”, page 49
⇒ “5.1.2 Assembly overview - activated charcoal filter, saloon”,
page 50
5.1.1 Assembly overview - activated charcoal filter, hatchback
1 - Breather line
2 - Pressure retention valve
with connecting hose
❑ From gravity valve on
fuel tank
3 - Breather connection
❑ Visible from below
4 - Bolt
❑ 10 Nm
5 - Throttle valve module -
J338-
❑ With intake connection.
6 - Activated charcoal filter sol‐
enoid valve 1 - N80-
❑ Valve closed with igni‐
tion switched off
❑ When engine is warm,
valve is activated
(pulsed) by engine con‐
trol unit - J623- .
7 - Connector
wheel housing.
5. Activated charcoal filter system 49

5.1.2 Assembly overview - activated charcoal filter, saloon
1 - Breather connection
wheel housing.
❑ To remove, pull off pres‐
sure retention valve -2-
and breather line -1-
(press securing ring
inwards)
❑ Then unclip activated
charcoal filter from
bracket.
3 - Pressure retention valve
with connecting hose
❑ From gravity valve on
fuel tank
4 - Breather line
5 - Activated charcoal filter sol‐
enoid valve 1 - N80-
❑ Valve closed with igni‐
tion switched off
❑ When engine is warm,
valve will be activated
(pulsed) by engine con‐
trol unit
6 - Intake manifold
5.2 Removing and installing activated char‐

coal filter
⇒ “5.2.1 Removing and installing activated charcoal filter, hatch‐
back”, page 50
5.2.1 Removing and installing activated char‐

coal filter, hatchback
Volkswagen Technical Site: http://vwts.ru http://vwts.info

♦ Open-end spanner insert AF 10 - V.A.G 1783/1-

Removing
– Release fuel lines -2- and -3- from activated charcoal filter
-1-, and pull them off in direction of -arrow-. Separate plug-in
– Unscrew bolt -arrow- from activated charcoal filter -1-.

– Release securing element -2- in direction of -arrow A-.

– Pull activated charcoal filter -1- downwards in direction of
-arrow B- out of bracket -3-.
Installing
– Install in reverse order of removal. The following should be
observed:
– Make sure that activated charcoal filter engages properly in
bracket.
– Do not interchange fuel lines.
– Ensure that fuel lines are tight.
Torque settings
page 49
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liner; Assembly overview- rear wheel housing liner .
5.3 Checking fuel tank breather

♦ Hand operated vacuum pump - VAS 6213-
♦ Adapter set - VAS 6550-

♦ Engine bung set - VAS 6122-
Check condition
• Ignition must be switched off.
Test sequence
Checking activated charcoal filter system solenoid valve 1 - N80- :
– Read event memory ⇒ Vehicle diagnostic tester.
– Disconnect line -2-. Separate plug-in connectors ⇒ page 43 .
– Using a connecting nipple - VAS 6213- and a standard hose,

connect hand vacuum pump - VAS 6550/3-1- to line leading
to active charcoal filter system solenoid valve 1 - N80- .

– Move slide ring -1- on hand vacuum pump - VAS 6213- to po‐
sition -B- for “pressure”.
– Using hand-operated vacuum pump - VAS 6213- , build up
pressure of approx. 0.1 bar.
• If pressure does »not« build up:
– Check line leading to activated charcoal filter solenoid valve 1

- N80- for leaks and damage. If no fault is detected, the sole‐
noid valve - N80- is leaking. Renew solenoid valve - N80- .
• If pressure builds up:
Activated charcoal filter solenoid valve 1 - N80- is not leaking.
Checking breather connection on activated charcoal filter

– Release and pull off breather line -2-. Separate plug-in con‐
nectors ⇒ page 43 .
– Connect hand vacuum pump - VAS 6213- with adapter set -

VAS 6550/3-2- to line -2- leading to activated charcoal filter.
– Move slide ring -1- on hand vacuum pump - VAS 6213- to po‐
sition -B- for “pressure”.
– Using hand-operated vacuum pump - VAS 6213- , build up
pressure of approx. 0.1 bar.
• If »no« pressure builds up:
– Breather connection is OK.

If pressure builds up:

– Check breather connection -3- on activated charcoal filter for
soiling and clean if necessary.
– Repeat check.
If pressure does not build up, short tail:

– Remove breather connection -3-.
– Seal activated charcoal filter using suitable workshop equip‐
ment.
– Operate hand vacuum pump - VAS 6213- several times. Pres‐
sure must build up.

If pressure does not build up, saloon:

– Remove cover for breather connection.
– Seal activated charcoal filter using suitable workshop equip‐
ment.
– Operate hand vacuum pump - VAS 6213- several times. Pres‐
sure must build up.
Continued for all vehicles (if pressure does not build up):
– Connect hand vacuum pump - VAS 6213- to activated char‐
coal filter.
– Operate hand vacuum pump - VAS 6213- several times. Vac‐
uum must build up.
If pressure does not build up:
– Renew activated charcoal filter.
If pressure builds up:
– Check lines between engine compartment and activated char‐
coal filter.
If pressure builds up and lines are OK:
Check activated charcoal filter solenoid valve 1 - N80- . To do this,
proceed as follows ⇒ page 53 :
Torque settings
page 49
♦ ⇒ “3 Plug-in connectors”, page 43
♦ Remove rear right wheel housing liner ⇒ General body re‐

6 Accelerator pedal
⇒ “6.1 Assembly overview - accelerator module”, page 57
6.1 Assembly overview - accelerator module
1 - Mounting bracket
2 - Connector
3 - 10 Nm
4 - Accelerator position sender
- G79- and accelerator position
sender 2 - G185-
❑ To remove, remove
pedal cluster cover.
6. Accelerator pedal 57
7 Fuel pump
⇒ “7.1 Checking fuel system pressurisation pump G6 ”,
page 58
7.1 Checking fuel system pressurisation

pump - G6-
⇒ “7.1.1 Checking function and voltage supply”, page 58
⇒ “7.1.2 Checking function and voltage supply, vehicles with en‐
gine codes CWVA, CWVB, CHYA, CHYB”, page 62
⇒ “7.1.3 Checking fuel pressure”, page 66
⇒ “7.1.4 Checking fuel pressure, vehicles with engine codes
CWVA, CWVB, CHYA, CHYB”, page 71
⇒ “7.1.5 Checking holding pressure”, page 76
⇒ “7.1.6 Checking holding pressure, vehicles with engine codes
⇒ “7.1.7 Checking fuel delivery rate”, page 86
⇒ “7.1.8 Checking delivery rate, vehicles with engine codes
⇒ “7.1.9 Checking current consumption”, page 101
7.1.1 Checking function and voltage supply

♦ Multimeter, e.g. hand-held multimeter - V.A.G 1526E-

♦ Adapter set - V.A.G 1594C-
♦ Vehicle diagnostic tester

Test conditions:
• Battery voltage must be at least 11.5 V. If necessary, charge
battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Charging
battery .
• Fuse for fuel pump control unit - J538- OK ⇒ Current flow di‐
agrams, Electrical fault finding and Fitting locations.
• Fuel pump control unit - J538- OK ⇒ Vehicle diagnostic tester.
Test sequence
Note
Function of fuel pump is checked using final control diagnosis.
7. Fuel pump 59
– Connect vehicle diagnostic tester -1- as follows:

– Connect diagnosis cable connector -2- to diagnostic connec‐
tion in driver footwell.
– Switch on ignition.
– Press following buttons on display one after the other:
♦ Vehicle self-diagnosis
♦ Engine electronics
♦ Final control diagnosis
♦ Electric fuel pump
♦ ►
♦ Button
The fuel pump must now run slowly up to maximum speed.
Note
The fuel pump runs very quietly.

If fuel pump does not run:
seats .
– Check that connector -arrow- on fuel pump control unit - J538-

is fitted securely by pulling connector without pressing catch.
If connector was not inserted correctly, repeat functional check
of fuel pump.
– Release connector -arrow- and pull it off fuel pump control unit
- J538- .
– Check contacts on connector and on fuel pump control unit -
J538- for damage.
– Check voltage supply between contacts -1- and -6- using mul‐
timeter .
– Use auxiliary measuring set - V.A.G 1594C- to do this.
– Switch on ignition or open driver door.
• Specification: approx. battery voltage
If specification is not obtained
– Locate and eliminate open circuit referring to current flow di‐
agram ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
If reading matches specification:


wedge - 3409- .
– Check that connector -1- on fuel pump control unit - J538- is

fitted securely by pulling connector without pressing catch. If
connector was not inserted correctly, repeat functional check
of fuel pump.
– Check contacts on plug and on fuel delivery unit for damage.
– Check wiring harness between fuel pump control unit - J538-
and fuel delivery unit ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.
CAUTION
7. Fuel pump 61


slightly.

– Check that electrical wires between flange and fuel pump are
connected.
– Check contacts for damage.
If no open circuit can be found:
– Fuel pump is defective; renew fuel delivery unit ⇒ page 30 .
7.1.2 Checking function and voltage supply,

vehicles with engine codes CWVA,
CWVB, CHYA, CHYB


Test conditions:
• Battery voltage must be at least 11.5 V. If necessary, charge
battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Charging
battery .
7. Fuel pump 63
• Fuse for fuel system pressurisation pump - G6- OK ⇒ Current

flow diagrams, Electrical fault finding and Fitting locations.
Test sequence
Note
Function of fuel pump is checked using final control diagnosis.
– Connect vehicle diagnostic tester -1- as follows:

– Connect diagnosis cable connector -2- to diagnostic connec‐
tion in driver footwell.
– Switch on ignition.
♦ ►
♦ Button
The fuel pump must now run slowly up to maximum speed.
Note
The fuel pump runs very quietly.

If fuel pump does not run:
seats .

wedge - 3409- .

– Check that connector -1- is fitted securely by pulling connector

without pressing catch. If connector was not inserted correctly,
repeat functional check of fuel pump.
– Check contacts on connector and on fuel delivery unit -3- for
damage.
– Test instrument adapter/DSO (5-pin) - VAS 5565- to connector

and fuel delivery unit.
– Connect multimeter - V.A.G 1526D- to cables -1- and -5- of
test instrument adapter/DSO (5-pin) - VAS 5565- .
– Initiate final control diagnosis again, and measure voltage at
fuel pump ⇒ page 64 .
• Specification: approx. battery voltage
– Locate and eliminate open circuit referring to current flow di‐
agram ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.

CAUTION

7. Fuel pump 65

slightly.

– Check that electrical wires between flange and fuel pump are
connected.
– Check contacts for damage.
If no open circuit can be found:
7.1.3 Checking fuel pressure



• Voltage supply OK. ⇒ page 58
CAUTION
– Connect pressure tester - VAS 6550- to fuel supply line with

adapter - VAS 6550/1- and -VAS 6550/2- .
– Connect hose - VAS 6550/1- to fuel supply line leading to en‐
gine.
– Connect hose - VAS 6550/2- to connection -B- of pressure
tester - VAS 6550- .
– Use hose - VAS 6550- to connect fuel line leading to fuel tank
with pressure tester - VAS 6550/2- .
– Ensure plug-in connectors are secure properly by pulling.
7. Fuel pump 67
– Ensure that drain tap -C- on pressure tester - VAS 6550- -1-
is closed.
– Shut-off taps -A- and -B- on pressure tester - VAS 6550- -1-
must be open.
– Connect the vehicle diagnostic tester .
♦ ►
♦ Button
Note
The fuel pump is now actuated to build up fuel pressure.
– Read off fuel pressure on pressure gauge.

• Specification: 4.0 … 7.0 bar
If fuel pressure is OK, check holding pressure ⇒ page 76 .
If the specification is exceeded:
– Check return line between fuel filter and fuel pump for kinks
and blockages.
If no fault is found:
– Pressure limiting valve in fuel filter is defective.
– Renew fuel filter.
– Check fuel pressure ahead of fuel filter. Adopt procedure as
follows to do this:
Checking fuel pressure before fuel filter:
– Pull fuel supply line -arrow- off fuel filter. Separate plug-in con‐
CAUTION

– Connect pressure tester - VAS 6550- between fuel filter and

fuel supply line with adapter - VAS 6550/1- and -VAS 6550/2- .
– Connect hose - VAS 6550/1- to fuel supply line leading to fuel
tank.
– Connect hose - VAS 6550/2- to connection -A- of pressure
– Use hose - VAS 6550- to connect fuel filter to pressure tester
- VAS 6550/2- .
is closed.
must be open.
– Repeat Final control diagnosis to build up fuel pressure.
– Check fuel lines for possible restrictions (kinks) or blockages.
– Check fuel line for leaks and damage.
– If fuel filter is soiled, renew it ⇒ page 47 .
– If pressure limiting valve in fuel filter is defective, renew fuel
filter ⇒ page 47 .
– Proceed as follows to check fuel pressure at fuel delivery unit:
Checking fuel pressure on fuel delivery unit:
seats .
7. Fuel pump 69

wedge - 3409- .
– Pull fuel lines -2- off fuel delivery unit. Separate plug-in con‐
CAUTION
– Connect pressure tester - VAS 6550- to fuel delivery unit -1-.

– Connect hose - VAS 6550/1- to fuel supply line -2- leading to
engine.
– Connect fuel delivery unit -1- to pressure tester - VAS 6550-
using hose - VAS 6550/2- .
is closed.
must be open.


– Remove fuel delivery unit ⇒ page 30 and check for contami‐
nation.
– Check that all hose connections -arrows- are connected.
– Check fuel lines for leaks and damage.
7.1.4 Checking fuel pressure, vehicles with

engine codes CWVA, CWVB, CHYA,
CHYB

• Voltage supply OK. ⇒ page 58
7. Fuel pump 71

CAUTION

adapter - VAS 6550/1- and -VAS 6550/2- .
– Connect hose - VAS 6550/1- to fuel supply line leading to en‐
gine.
– Connect hose - VAS 6550/2- to connection -B- of pressure
– Use hose - VAS 6550- to connect fuel line leading to fuel tank
with pressure tester - VAS 6550/2- .

is closed.
must be open.
♦ ►
♦ Button
Note
The fuel pump is now actuated to build up fuel pressure.

• Specification: 4.0 bar.
If fuel pressure is OK, check holding pressure ⇒ page 76 .
If the specification is exceeded:
– Check return line between fuel filter and fuel pump for kinks
and blockages.
– Pressure limiting valve in fuel filter is defective.
– Renew fuel filter.
– Check fuel pressure ahead of fuel filter. Adopt procedure as
follows to do this:
Checking fuel pressure before fuel filter:
CAUTION
7. Fuel pump 73

fuel supply line with adapter - VAS 6550/1- and -VAS 6550/2- .
– Connect hose - VAS 6550/1- to fuel supply line leading to fuel
tank.
- VAS 6550/2- .
is closed.
must be open.
– If fuel filter is soiled, renew it ⇒ page 47 .
– If pressure limiting valve in fuel filter is defective, renew fuel
filter ⇒ page 47 .
– Proceed as follows to check fuel pressure at fuel delivery unit:
Checking fuel pressure on fuel delivery unit:
seats .

wedge - 3409- .

– Pull fuel lines -2- off fuel delivery unit. Separate plug-in con‐
CAUTION

engine.
is closed.
must be open.

– Remove fuel delivery unit ⇒ page 30 and check for contami‐
nation.
7. Fuel pump 75
7.1.5 Checking holding pressure

♦ Pressure gauge - VAS 6550-

• Voltage supply OK.
• Fuel pressure OK ⇒ page 66 .
– Pull off supply line -1-. Separate plug-in connectors
⇒ page 43 .
CAUTION

– Connect hose - VAS 6550/1- between fuel line to engine and

shut-off tap -B-.
– Connect hose - VAS 6550/2- between fuel line from fuel tank
and shut-off tap -A-.
– Ensure that drain tap -C- on pressure tester -1- is closed.

– Shut-off taps -A- and -B- are open.
Test sequence
– Select final control diagnosis for fuel pump in vehicle self-di‐
agnosis program.
Note
♦ The fuel pump is now actuated to build up fuel pressure.

♦ If the final control diagnosis is to be carried out several times
in succession, it may be necessary to start the engine briefly
before repeating the final control diagnosis.

• Specification: ≥ 4.0 bar
– End self-diagnosis, and switch off ignition.
– Observe pressure drop on pressure gauge. After 10 minutes,
the pressure must not drop by more than 1.0 bar.
If the pressure drops further:
– Check all fuel lines for leaks and damage.
If no fault is detected:
– Actuate fuel pump with final control diagnosis to build up fuel
pressure.
7. Fuel pump 77
– After pressure has built up, close shut-off tap -B- of pressure
tester immediately. Lever is then at right angle to direction of
flow.
If the pressure now drops (leak on fuel tank side):
Check fuel pressure before fuel filter as described here:
⇒ page 78 .
If the pressure does not drop now (leak on engine side):
Note
Search for leak on engine side. Repeat holding pressure check.

This time, close shut-off tap -A- to check whether leak actually is
on engine side.
– If there is a leak on engine side, carry out external check of

fuel pipes and high-pressure pump for leaks.
If no fault can be determined, check the injectors for leaks:
– Remove spark plugs.
– Open shut-off valves -A- and -B-. Actuate fuel pump with final
control diagnosis.
– Check through spark plug holes whether fuel has collected on
piston crown due to a leaking injector.
Checking holding pressure before fuel filter:

CAUTION


fuel supply line using hose - VAS 6550/1- and -VAS 6550/2- .
– Connect hose - VAS 6550/1- to fuel line leading to fuel tank.
- VAS 6550/2- .
is closed.
must be open.
– After pressure has built up, close shut-off valve -A- of pressure
flow.
– Observe pressure drop on pressure gauge.
If the pressure does not drop:
Check for leaks in components located further towards engine.
– Check fuel filter for leaks and damage.
If the pressure drops:
– Proceed as follows to check residual pressure on fuel delivery
unit:
Checking residual pressure on fuel delivery unit:
seats .
– If fitted, unclip fuel pump control unit - J538- -2- from cover
-1-.
7. Fuel pump 79

wedge - 3409- .
CAUTION

engine.

is closed.
must be open.
flow.
In the event of leaks, check components which are located further
towards fuel filter.

– Pressure retention valve in fuel pump is defective.
– Renew fuel delivery unit ⇒ page 30 .
7.1.6 Checking holding pressure, vehicles

with engine codes CWVA, CWVB,
CHYA, CHYB
7. Fuel pump 81

• Voltage supply OK ⇒ page 62 .
– Pull off supply line -1-. Separate plug-in connectors
⇒ page 43 .
CAUTION
– Connect hose - VAS 6550/1- between fuel line to engine and

shut-off tap -B-.
– Connect hose - VAS 6550/2- between fuel line from fuel tank
and shut-off tap -A-.

– Ensure that drain tap -C- on pressure tester -1- is closed.

– Shut-off taps -A- and -B- are open.
Test sequence
– Select final control diagnosis for fuel pump in vehicle self-di‐
agnosis program.
Note
♦ The fuel pump is now actuated to build up fuel pressure.

♦ If the final control diagnosis is to be carried out several times
in succession, it may be necessary to start the engine briefly
before repeating the final control diagnosis.

• Specification: ≥ 4.0 bar
– End self-diagnosis, and switch off ignition.
– Observe pressure drop on pressure gauge. After 10 minutes,
the pressure must not drop by more than 1.0 bar.
If the pressure drops further:
– Check all fuel lines for leaks and damage.
– Actuate fuel pump with final control diagnosis to build up fuel
pressure.
flow.
If the pressure now drops (leak on fuel tank side):
Check fuel pressure before fuel filter as described here:
⇒ page 84 .
If the pressure does not drop now (leak on engine side):
Note
Search for leak on engine side. Repeat holding pressure check.

This time, close shut-off tap -A- to check whether leak actually is
on engine side.
If there is a leak on engine side:

– Check surfaces of fuel lines for leaks.
– Check surfaces of fuel rail and injectors for leaks ⇒ Rep. gr.
24 ; Injectors; Assembly overview - fuel rail with injectors .
– Check injectors for leaks ⇒ Rep. gr. 24 ; Injectors; Checking
injectors .
7. Fuel pump 83
Checking holding pressure before fuel filter:

CAUTION

fuel supply line using hose - VAS 6550/1- and -VAS 6550/2- .
– Connect hose - VAS 6550/1- to fuel line leading to fuel tank.
- VAS 6550/2- .

is closed.
must be open.
– After pressure has built up, close shut-off valve -A- of pressure
flow.
Check for leaks in components located further towards engine.
– Check fuel filter for leaks and damage.
– Proceed as follows to check residual pressure on fuel delivery
unit:
Checking residual pressure on fuel delivery unit:
seats .

wedge - 3409- .
CAUTION
7. Fuel pump 85

engine.
is closed.
must be open.
flow.
In the event of leaks, check components which are located further
towards fuel filter.

– Pressure retention valve in fuel pump is defective.
7.1.7 Checking fuel delivery rate


equipment required

♦ Remote control for V.A.G 1348 - V.A.G 1348/3A-
♦ Pressure regulating valve - VAS 6550/4-
7. Fuel pump 87

♦ Measuring container, capacity ≥ 3 litre
Note
When driving characteristic problems occur when the fuel tank is

a approx. 1/4 filled, then check fuel delivery rates with approx. 1/
4 filled tank or less.

• Battery voltage at least 11.5 V.
– Connect battery charger ⇒ Electrical system; Rep. gr. 27 ;
Battery; Charging battery .
Checking fuel delivery rate, quick test:
Note
The fuel delivery rate must first be checked in the engine com‐
partment with the help of the function “Checking fuel delivery rate,
quick test”. If the minimum delivery rate is not obtained, perform
a 2nd measurement on the fuel delivery unit.

– Start Guided Functions.
– Select "Check fuel delivery rate, quick test".
Proceed as follows to check fuel delivery rate:
Checking fuel delivery rate in engine compartment:
seats .


wedge - 3409- .
– Connect test instrument/DSO adapter (5-pin) - VAS 5565- to

– Connect remote control - V.A.G 1348/3A- to adapter - VAS
5565- and to battery positive terminal in engine compartment.
Note
engine is stopped.
7. Fuel pump 89
– The quantity delivered by the fuel pump depends on the bat‐

tery voltage. Therefore, also connect multimeter to outputs
-1- and -5- of test instrument/DSO adapter 5-pin - VAS 5565- .
– Connect multimeter with auxiliary measuring set - V.A.G
1594C- .
– Release and pull off fuel supply line. Separate plug-in con‐
CAUTION
– Using hose - VAS 6550- , connect pressure tester - VAS

6550/2- to fuel supply line coming from fuel tank.
– Connect pressure regulating valve - VAS 6550/4- to connec‐
tion -B- of pressure tester - VAS 6550- .
– Hold end of hose of pressure regulating valve - VAS 6550/4-
in measuring container.

is closed.
must be open.
Test sequence
– Hold container in front of open connection of pressure tester -
VAS 6550- .
– Press remote control - V.A.G 1348/3A- .
Note
The fuel system pressurisation pump - G6- will be actuated.
– Read pressure shown by pressure tester - VAS 6550- .
– Adjust pressure on pressure regulating valve - VAS 6550/4- to

4.5 bar.
– Set pressure on pressure regulating valve - VAS 6550/4- using
adjuster wheel -arrow-.
– From this point on do not change position of adjuster wheel
any more.
– Drain measuring container.
– Press remote control for 60 seconds whilst measuring voltage
at fuel pump.
– Compare delivered quantity of fuel with specification indicated

in chart.
Name of axis Unit
Minimum delivery rate cm3
Voltage at fuel pump with en‐ Volt
gine not running and pump run‐
ning.
Reading example:
During the test a voltage of 10.5 volts is measured. This equates
to a minimum delivery rate of approx. 1200 cm3 in 60 seconds.
7. Fuel pump 91

– Repeat test ⇒ page 91
– Check fuel tank breather ⇒ page 52 .
Check fuel delivery rate at fuel filter as follows:
Checking fuel delivery rate at fuel filter:

CAUTION

adapter - VAS 6550/1- .
tion -A- of pressure tester - VAS 6550- .

is closed.
must be open.
– Repeat fuel delivery rate check ⇒ page 91 .
– Check fuel filter, renew if necessary ⇒ page 47 .
Proceed as follows to check fuel delivery rate at fuel delivery unit:
Checking fuel delivery rate on fuel delivery unit:

– Pull off fuel supply line -3- (black). Separate plug-in connectors
⇒ page 43 .
CAUTION
– Connect pressure tester - VAS 6550- with hose - VAS 6550/2-

to fuel delivery unit -1-.
– Connect hose - VAS 6550/2- to shut-off tap -A-.
– Connect pressure regulator valve - VAS 6550/4- to connection
-B- of pressure tester - VAS 6550- .
7. Fuel pump 93
is closed.
must be open.
– Check filter strainer for soiling.

– Check that all fuel delivery unit -1- hose connections
-arrows- are connected.
7.1.8 Checking delivery rate, vehicles with engine codes CWVA, CWVB, CHYA,
CHYB


equipment required

♦ Remote control for V.A.G 1348 - V.A.G 1348/3A-
♦ Pressure regulating valve - VAS 6550/4-
7. Fuel pump 95

♦ Measuring container, capacity ≥ 3 litre
Note
When driving characteristic problems occur when the fuel tank is

a approx. 1/4 filled, then check fuel delivery rates with approx. 1/
4 filled tank or less.

• Battery voltage at least 11.5 V.
– Connect battery charger ⇒ Electrical system; Rep. gr. 27 ;
Battery; Charging battery .
seats .
wedge - 3409- .


– Connect remote control - V.A.G 1348/3A- to adapter - VAS
5565- and to battery positive terminal in engine compartment.
Note
engine is stopped.
– The quantity delivered by the fuel pump depends on the bat‐

tery voltage. Therefore, also connect multimeter to outputs
-1- and -5- of test instrument/DSO adapter 5-pin - VAS 5565- .
1594C- .
– Release supply line -1- and pull it off. Separate plug-in con‐
CAUTION
7. Fuel pump 97
– Using hose - VAS 6550- , connect pressure tester - VAS

6550/2- to fuel supply line coming from fuel tank.
tion -B- of pressure tester - VAS 6550- .
is closed.
must be open.
Test sequence
CAUTION
– Hold container in front of open connection of pressure tester -

VAS 6550- .
– Press remote control - V.A.G 1348/3A- .
Note
The fuel system pressurisation pump - G6- will be actuated.
– Read pressure shown by pressure tester - VAS 6550- .

– Adjust pressure on pressure regulating valve - VAS 6550/4- to

4.0 bar.
– Set pressure on pressure regulating valve - VAS 6550/4- using
adjuster wheel -arrow-.
– From this point on do not change position of adjuster wheel
any more.
– Drain measuring container.
– Press remote control for 60 seconds whilst measuring voltage
at fuel pump.
Specified value
• Voltage at fuel pump: approx. 12 V.
• Minimum delivery rate is approx. 1000 cm 3 in 60 s.

– Repeat test ⇒ page 98
– Check fuel tank breather ⇒ page 52 .
Check fuel delivery rate at fuel filter as follows:
Checking fuel delivery rate at fuel filter:

CAUTION
7. Fuel pump 99

adapter - VAS 6550/1- .
tion -A- of pressure tester - VAS 6550- .
is closed.
must be open.
– Check fuel filter, renew if necessary ⇒ page 47 .
Proceed as follows to check fuel delivery rate at fuel delivery unit:
Checking fuel delivery rate on fuel delivery unit:

– Pull off fuel supply line -3- (black). Separate plug-in connectors
⇒ page 43 .
CAUTION

– Connect pressure tester - VAS 6550- with hose - VAS 6550/2-

to fuel delivery unit -1-.
– Connect hose - VAS 6550/2- to shut-off tap -A-.
– Connect pressure regulator valve - VAS 6550/4- to connection
-B- of pressure tester - VAS 6550- .
is closed.
must be open.
– Check filter strainer for soiling.

– Check that all fuel delivery unit -1- hose connections
-arrows- are connected.
7.1.9 Checking current consumption

7. Fuel pump 101


• Voltage supply OK.
seats .



wedge - 3409- .
– Check that connector -1- on fuel pump control unit - J538- is

fitted securely by pulling connector without pressing catch. If
connector was not inserted correctly, repeat functional check
of fuel pump.
– Check contacts on plug and on fuel delivery unit for damage.
– Connect multimeter to outputs -1- and -5- of test instrument/

DSO adapter 5-pin - VAS 5565- .
1594C- .
7. Fuel pump 103

– Connect test instrument adapter/DSO (5-pin) - VAS 5565- to

– Connect pick-up clamp -A- to red terminal with lettering “pick-
up clamp” for test instrument adapter/DSO (5-pin) - VAS
5565- .
– Start engine and run it at idling speed.
– Check current draw of fuel pump using multimeter.
• Specification: max. 9 A.
Note
♦ The starting current for the fuel pump can be briefly above
specifications when starting the engine.
♦ If the fault in the fuel system is only sporadically evident, the
check can also be carried out during a road test. A 2nd person
is required to do this, however.
If the current draw is exceeded:

– Check strainer of fuel delivery unit for soiling.
– Check fuel tank for soiling.
– Check fuel delivery unit for soiling.
– Fuel pump is defective, renew fuel delivery unit ⇒ page 30 .

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Service

Service Department. Technical Information

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.1 Safety regulations for working on fuel supply

Danger of fire caused by escaping fuel

– Have a second person operate the test and measuring equip‐

1.3 Safety measures when working on vehicles with a start/stop system

2 Rep. gr.00 - Technical data

2.1 Engine number/engine data

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

3.1 Rules for cleanliness when working on

4 Rep. gr.00 - Technical data

20 – Fuel supply system

1.1 Assembly overview - fuel tank

1.1.1 Assembly overview - fuel tank, hatchback

6 Rep. gr.20 - Fuel supply system

Installation position of fuel delivery unit

Checking breather valve

Before installing breather valve remove fuel tank cap.

Earth connection for fuel filler neck

1.1.2 Assembly overview - fuel tank, saloon

8 Rep. gr.20 - Fuel supply system

Installation position of fuel delivery unit

Checking breather valve

Before installing breather valve remove fuel tank cap.

1.2 Emptying fuel tank

1.2.1 Emptying fuel tank when fuel pump is intact

Special tools and workshop

♦ Removal wedge - 3409-

10 Rep. gr.20 - Fuel supply system

– Pull off supply line (metal connector) -1-. Separate plug-in

– Collect escaping fuel with a cleaning cloth.

Vehicles with fuel pump control unit - J538- :

Continued for all vehicles:

– Pull off connector -arrow-.

– Connect test instrument adapter/DSO (5-pin) - VAS 5565- to

– Open tank flap unit.

12 Rep. gr.20 - Fuel supply system

1.2.2 Emptying fuel tank if it is more than 3/4

♦ Fuel extractor - VAS 5190 A- for E 85 fuel (not shown).

– Make a mark -arrow- at dimension -a- from end of extraction

– Open tank flap unit.

– Drain fuel tank via filler neck as far as possible.

♦ When no more fuel is extracted, the tank is emptied just

1.2.3 Emptying fuel tank if it is less than 3/4 full

14 Rep. gr.20 - Fuel supply system

Special tools and workshop

♦ Key for union nut - 3217-

Separate plug-in connectors ⇒ page 43 .

– Fold up bench seat ⇒ General body repairs, interior; Rep. gr.

Continued for all vehicles:

– Release connector -1- and pull off.

16 Rep. gr.20 - Fuel supply system

Vehicles with union nut:

Vehicles with locking ring:

Continued for all vehicles:

1.3 Removing and installing fuel tank

1.3.1 Removing and installing fuel tank,