VW Golf 6 Fuel Supply System Petrol Engines Eng

Service
Workshop Manual
Golf 2009 ➤
Golf Plus 2009 ➤
Fuel supply system, petrol engines
Engine ID
CDL CAV CAV CAV CBZ CBZ CBT CBU CTH
G B C D A B A A D
CTK
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.
Golf 2009 ➤ , Golf Plus 2009 ➤
Fuel supply system, petrol engines - Edition 08.2018
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Safety regulations for working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Safety precautions for when using test and measuring equipment during a road test . . . . 4
2.3 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 4
3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1 Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2 Fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.1 Assembly overview - fuel delivery unit/fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.2 Removing and installing fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . 31
2.3 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3 Plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.1 Separating plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.1 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.2 Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.1 Assembly overview - activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.2 Removing and installing activated charcoal filter, engine codes CBTA, CBUA . . . . . . . . . . 47
5.3 Checking fuel tank breather, engine codes CDLG, CAVB, CAVC, CAVD, CBZA, CBZB,
CTHD, CTKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.4 Checking fuel system for leaks, engine codes CBTA, CBUA . . . . . . . . . . . . . . . . . . . . . . . . 50
5.5 Schematic diagram of activated charcoal filter system, engine codes CBTA, CBUA . . . . 57
5.6 Removing and installing fuel system diagnostic pump (CBTA, CBUA) . . . . . . . . . . . . . . . . 59
6 Accelerator pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6.1 Assembly overview - accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6.2 Removing and installing accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7 Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7.1 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Contents i
ii Contents
00 – Technical data
1 Engine data
(VRL012071; Edition 08.2018)
Codes CBZA CBZB CAVB CAVC CAVD
Exhaust emission standard EU 5 EU 5 EU 5 EU 5 EU 5
Displacement l 1.2 1.2 1.4 1.4 1.4
Power kW 63 77 125 103 118
RON 95 unleaded 95 unleaded 95 unleaded 95 unleaded 95 unleaded
Codes CDLG CBTA CBUA CTHD, CTKA

Exhaust emission standard EU 5 Tier2/BIN5 (US SULEV EU 5
Fed. Gov.)
Displacement l 2.0 2.5 2.5 1.4
Power kW 173 125 125 118
RON 95 unleaded 95 unleaded1) 95 unleaded1) 95 unleaded
1)In exceptional circumstances min. 91 RON, however with re‐
duced performance.
Volkswagen Technical Site: http://vwts.ru http://vwts.info
1. Engine data 1
2 Safety precautions
⇒ “2.1 Safety regulations for working on fuel supply”, page 2
⇒ “2.2 Safety precautions for when using test and measuring
equipment during a road test”, page 4
⇒ “2.3 Safety measures when working on vehicles with a start/
stop system”, page 4
2.1 Safety regulations for working on fuel

supply
WARNING
The fuel pressure in the high-pressure pipe can reach 120 bar!
Observe the safety precautions when releasing pressure in the
high-pressure section.
♦ Releasing pressure in high-pressure section ⇒ Rep. gr.
24 ; Releasing pressure in high-pressure section .
♦ Fuel supply line is pressurised. 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 release pressure by carefully
pulling hose off connection.
For reasons of safety, the power supply to the fuel pump must
be interrupted before the fuel system is opened. The fuel pump
would otherwise be activated when the driver's door is opened.
Use one of the following options to interrupt the power supply:
♦ Disconnect battery.
Or
♦ Remove fuse for fuel system pressurisation pump - G6- .
Or
♦ Remove fuse for fuel pump control unit - J538- or for fuel
delivery unit.
Or
♦ Pull off connector from fuel delivery unit flange or fuel
pump control unit - J538- .
Caution
Observe the following points during all installation work, in par‐

ticular in the engine compartment, due to the space limitations:
♦ Route lines of any kind so that the original routing can be
restored.
♦ Ensure that there is sufficient clearance to all components.
When removing and installing fuel gauge sender - G- or fuel pump

(fuel delivery unit) from a full or partly full fuel tank, observe the
following:
Interrupt current to fuel pump ⇒ page 2 .
2 Rep. gr.00 - Technical data

WARNING
Fuel system is under pressure! Wear eye protection and pro‐

tective gloves to avoid injuries and skin contact. Wrap a cloth
around the connection before loosening hose connections.
Then release pressure by carefully pulling hose off connection.
Before starting work on the fuel supply system, the following steps
must be performed:
♦ Before starting work, the extraction hose of a switched-on ex‐
haust gas extraction system must be laid near to the assembly
opening of the fuel tank.
♦ It is used to extract fuel fumes.
♦ If no exhaust gas extraction system is available, a radial fan
with a displacement greater than 15 m3/h can be used provid‐
ing that motor is not in air flow.
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
When removing and installing, the fuel tank must be empty, be‐
cause otherwise it is too heavy ⇒ page 6 .
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.
To prevent injuries to persons and/or damage to the injection and

ignition system, the following must be observed:
♦ Do not touch or pull off ignition coils with output stage when
engine is running or turning at starter speed.
♦ Switch off ignition before connecting or disconnecting injection
and ignition system wiring as well as test instrument cables.
2. Safety precautions 3
2.2 Safety precautions for when using test

and measuring equipment during a road
test
During road tests in which test and measuring equipment is used,
please observe the following:
WARNING
Risk of accidents due to distraction and inadequate securing

of test and measuring equipment.
♦ Operation of test and measuring equipment while driving
results in distraction.
♦ Increased risk of injury due to inadequately secured test
and measuring equipment.
♦ Test and measuring equipment must always be secured
on the rear seat.
♦ A second person must operate the test and measuring
equipment.
♦ The person operating the test and measuring equipment
must be seated in the rear.
♦ Never operate the test and measuring equipment while
sitting in the front passenger seat.
♦ In the event of an accident, the person may receive seri‐
ous injuries when the front passenger airbag is triggered.
2.3 Safety measures when working on ve‐

hicles with a start/stop system
Please note the following when working on vehicles with a start/
stop system:
WARNING
Risk of injury due to automatic start of engine in vehicles with

start/stop system.
♦ If the start/stop system of a vehicle is activated, the engine
may start automatically.
♦ This is indicated by a message in the dash panel insert.
♦ Therefore, ensure that the start/stop system is deactivated
when working on vehicle (switch ignition off, switch ignition
on again as required).
4 Rep. gr.00 - Technical data

3 General repair instructions

⇒ “3.1 Rules for cleanliness”, page 5
3.1 Rules for cleanliness

When working on the fuel supply/injection system, carefully follow
the “5 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.
3. General repair instructions 5

20 – Fuel supply system

1 Fuel
⇒ “1.1 Assembly overview - fuel tank”, page 6
⇒ “1.2 Removing and installing fuel tank”, page 10
⇒ “1.3 Emptying fuel tank”, page 18
1.1 Assembly overview - fuel tank

⇒ “1.1.1 Assembly overview - fuel tank, engine codes CDLG,
CAVB, CAVC, CAVD, CBZA, CBZB, CTHD, CTKA”, page 6
⇒ “1.1.2 Assembly overview - fuel tank, engine codes CBTA,
CBUA”, page 8
1.1.1 Assembly overview - fuel tank, engine codes CDLG, CAVB, CAVC, CAVD,
CBZA, CBZB, CTHD, CTKA
1 - Securing bolt
2 - Cap
❑ Renew if damaged
3 - Earth connection
❑ Check for secure seat‐
ing.
4 - 10 Nm
5 - Wiring guide
6 - 25 Nm
❑ Renew
❑ To secure the securing
straps for the fuel tank,
only bolts with loose
washers must be used.
If different bolts are
used, the securing
straps might twist during
tightening. Bolts ⇒ ET‐
KA (Electronic parts
catalogue) .
7 - Fuel
❑ When removing, sup‐
port using engine and
gearbox jack - V.A.G
1383 A- .
❑ Removing and installing
⇒ page 10
8 - Clamping washer
9 - Exhaust system retainer
10 - Securing strap
❑ Observe installation po‐
sition
11 - Heat shield
❑ Various designs
6 Rep. gr.20 - Fuel supply system

12 - Supply line
❑ To fuel rail
❑ Check for secure seating.
13 - Fuel filter
❑ Arrow points in direction of flow.
14 - Breather line
❑ Clipped onto side of fuel tank.
15 - Seal
❑ Renew
❑ When installing, fit dry in fuel tank opening.
❑ Moisten with fuel only when installing flange.
16 - Fuel delivery unit
❑ Removing and installing ⇒ page 31
❑ Checking fuel pump ⇒ page 63 .
❑ Note installation position on fuel tank ⇒ page 7
❑ With fuel gauge sender - G-
❑ Removing and installing fuel gauge sender - G- ⇒ page 36
17 - Locking ring 110 Nm
❑ Remove and install using wrench - T10202- .
18 - Supply line
❑ black
❑ Ensure proper seating.
❑ Open at separating point ⇒ page 38
19 - Return line
❑ blue
20 - Tank flap unit
❑ With rubber cup.
❑ Removing and installing ⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit; Removing and
installing fuel tank flap unit .
Installation position of fuel delivery unit

• Tab -2- on flange must be between lugs -1- and -3- on fuel
tank.
• -Arrow- points in direction of travel.
1. Fuel 7
1.1.2 Assembly overview - fuel tank, engine codes CBTA, CBUA
1 - Securing bolt
2 - Earth connection
ing.
3 - Vacuum line
❑ To fuel system diagnos‐
tic pump - V144-
4 - 10 Nm
5 - Rivet
6 - Protective plate
❑ Riveted as standard to
bottom clamp
❑ When replacing the fuel
tank, place protective
plate on filler neck and
rivet clamp (holes in pro‐
tective plate must be
aligned with holes in fill‐
er neck).
7 - Wiring guide
❑ For ABS line
❑ Clipped onto protective
plate
8 - 25 Nm
❑ Renew
❑ To secure the securing
straps for the fuel tank,
only bolts with loose
washers must be used.
If different bolts are
used, the securing
straps might twist during
tightening.
9 - Fuel
10 - Clamping washer
11 - Exhaust system retainer
12 - Securing strap
❑ Observe installation position
13 - Heat shield
14 - Supply line
❑ To fuel rail
15 - Fuel filter
❑ Installation position: arrow in direction of flow.
16 - Vacuum line
❑ From fuel system diagnostic pump - V144- to intake manifold.

❑ Clipped onto fuel tank
17 - Breather line
❑ From activated charcoal filter to activated charcoal filter solenoid valve 1 - N80-
❑ Clipped onto fuel tank
18 - Seal
❑ Renew
❑ When installing, fit dry in fuel tank opening.
❑ Moisten with fuel on inside only when installing fuel delivery unit.
❑ Checking fuel pump ⇒ page 63 .
❑ Note installation position in fuel tank ⇒ page 10 .
❑ With fuel gauge sender - G-
❑ Removing and installing fuel gauge sender - G- ⇒ page 36
❑ Clean strainer if soiled.
20 - Locking ring
❑ Remove and install using fuel tank sender unit tool - 3087- .
❑ 110 Nm
21 - Return line
❑ blue
22 - Cap
❑ Renew seal if damaged.
23 - Tank flap unit
❑ With rubber cup.
❑ Removing and installing ⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit
24 - To activated charcoal filter
25 - Supply line
❑ black
1. Fuel 9
Installation position of fuel delivery unit

Tab -2- on fuel delivery unit must be between tabs -1- and -3-.
Note
♦ -Arrow- points in direction of travel.

♦ Fuel delivery unit can be installed only in this position.
1.2 Removing and installing fuel tank

⇒ “1.2.1 Removing and installing fuel tank, engine codes CDLG,
CAVB, CAVC, CAVD, CBZA, CBZB, CTHD, CTKA”, page 10
⇒ “1.2.2 Removing and installing fuel tank, engine codes CBTA,
CBUA”, page 14
1.2.1 Removing and installing fuel tank, en‐

gine codes CDLG, CAVB, CAVC,
CAVD, CBZA, CBZB, CTHD, CTKA
Special tools and workshop equipment required
♦ Torque wrench (5 … 50 Nm) - V.A.G 1331-
♦ Engine and gearbox jack - V.A.G 1383 A-
Removing fuel tank

– Note safety precautions ⇒ page 2 .
– Observe rules for cleanliness ⇒ page 5 .
– Unscrew tank flap unit securing bolt and remove tank flap unit
⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit .

– Drain fuel tank and clean fuel filler neck and surrounding area
⇒ page 18 .
– Remove bench seat ⇒ General body repairs, interior; Rep. gr.
72 ; Rear seats; Removing and installing bench seat / individ‐
ual seats .
– Remove cover -1- with fuel pump control unit - J538- -2- from
fuel delivery unit.
– Unclip cover -1- at retaining tabs -arrows-, using removal

wedge - 3409- .
– Pull off connector -arrow-.
Note
For vehicles with auxiliary heater the metering pump - V54- con‐
nector must be separated additionally.
– 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; Removing
and installing wheel housing liner .
– Undo and remove bolts -1- from filler neck in body structure.
– Unclip and remove wire from filler neck -2-.
1. Fuel 11
– Loosen clamping sleeve -arrows-.
– Remove rear cross member for underbody. To do this, un‐

screw nuts -1- and -2-.
Note
The aid of a 2nd mechanic is required to remove the rear part of

the exhaust system.
– Remove centre silencer and rear silencer ⇒ Rep. gr. 26 ;

Exhaust system/silencer; Assembly overview - silencers .
WARNING
Fuel supply lines are under pressure! Wear eye protection and
protective gloves to avoid injuries and skin contact. Wrap a
cloth around the connection before loosening hose connec‐
tions. Then release pressure by carefully pulling hose off con‐
nection.
– Disconnect breather line -1- (white) and supply line -2- (black)
at connecting point. Separate plug-in connectors
⇒ page 38 .
Note
Vehicles with auxiliary heater, the fuel line of the metering pump
- V54- must also be separated.
– Unscrew bolts -1- and -3-.

– Place engine and gearbox jack - V.A.G 1383 A- under fuel tank
to support it.
– Unscrew bolts -2- and -4-.
Note
The aid of a second mechanic is required to remove the fuel tank.
– Lower fuel tank and guide it out of the body structure.

Installing:
Install in reverse order of removal. During this procedure, observe
the following:
– With the aid of a 2nd mechanic, guide the filler neck in between
rear axle and body.
– Slowly raise fuel tank into installation position.

– Secure fuel tank with bolts -1- through -4-.
Note
♦ To secure the securing straps for the fuel tank, only bolts with
loose washers must be used. This will stop the securing straps
from being twisted out of position when tightening the bolts.
♦ Plug-in connectors for fuel lines must engage »audibly« when
joined.
♦ Note colour assignment when installing the plug-in connectors
⇒ page 38 .
♦ Ensure plug-in connector is secured properly by pulling it.
♦ Separate plug-in connectors ⇒ page 38 .
♦ Note installation position of earth connection.

♦ 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 the engine and gearbox jack - V.A.G 1383 A- .
♦ Install breather lines and fuel lines free of kinks.
♦ Ensure that line connections are tight.
♦ After installing fuel tank, check that the supply, return and
breather lines are still clipped onto the fuel tank.
1. Fuel 13
– Note installation position of earth connection.

– Check whether there are signs of oxidation on the earth wire
of the connectors, remove if necessary.
• Ensure that connector -2- is seated securely on metal ring
-3-.
• Contact tab -1- must be hooked into fuel tank -4- and secured
by means of spacer bush -5-.
Caution
Risk of explosion due to electrostatic discharge.

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.
– Fill fuel tank with at least 5 litres of fuel.
WARNING

Specified torque
Component Specified torque
Filler neck of fuel tank to body 10 Nm
Fuel tank to underbody 25 Nm
Bench seat ⇒ General body repairs, interior; Rep. gr. 72 ; Rear
seat; Removing and installing bench seat / individual
seats
Exhaust system ⇒ Exhaust system; Rep. gr. 26 ; Exhaust pipes/si‐
lencers; Assembly overview - silencers
Tank flap unit ⇒ General body repairs, exterior; Rep. gr. 55 ; Tank
flap unit; Removing and installing tank flap unit .
1.2.2 Removing and installing fuel tank, en‐

gine codes CBTA, CBUA

♦ Torque wrench - V.A.G 1331-
Removing
• The fuel tank must not be more than 1/4 full.
Note
Drain fuel tank with fuel extractor - VAS 5190- ⇒ page 18 .

– Remove wheel lock adapter from luggage compartment.
– Open fuel tank flap and remove fuel tank cap.
– Unscrew tank flap unit securing bolt and remove tank flap unit
⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit .
72 ; Rear seats; Removing and installing bench seat .
– Unclip cover -1- of fuel delivery unit. Arrow -2- points in direc‐
tion of travel.
Note
For vehicles with auxiliary heater the metering pump - V54- con‐
nector must be separated additionally.
– Detach connector -1- from fuel delivery unit.

pairs, exterior; Rep. gr. 66 ; Wheel housing liner .
1. Fuel 15
– Disconnect connectors -1- and -2-.

– Unbolt filler neck from body -arrows-.
– Unclip ABS line -A- from retainer -arrows-.

– Remove exhaust system.
WARNING
Fuel supply lines are under pressure! Wear eye protection and
protective gloves to avoid injuries and skin contact. Wrap a
cloth around the connection before loosening hose connec‐
tions. Then release pressure by carefully pulling hose off con‐
nection.
– Disconnect white breather line -1-, black supply line -2- and
green vacuum line for fuel system diagnostic pump - V144-
-3- at connection. Separate plug-in connectors ⇒ page 38 .
Note
During the further procedure, a second mechanic is required to

support the fuel tank.
– Remove securing strap and securing bolts -arrows-.

– Turn fuel tank out to side.
Installing
Installation is performed in the reverse order of removal. During
this procedure, observe the following:
♦ Install breather lines and fuel lines free of kinks.
♦ Do not interchange supply line and return line (return line blue,
supply line black).
♦ Ensure that line connections are tight.
♦ After installing fuel tank, check that lines are still clipped onto
the fuel tank.

– Note installation position of earth connection.

– Check whether there are signs of oxidation on the earth wire
of the connectors, remove if necessary.
• Ensure that connector -2- is seated securely on metal ring
-3-.
• Contact tab -1- must be hooked into fuel tank -4- and secured
by means of spacer bush -5-.
Caution
Risk of explosion due to electrostatic discharge.

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.
– Fill fuel tank with at least 5 litres of fuel.
WARNING

– Bleed fuel system ⇒ Rep. gr. 23 ; Fuel preparation, injection;

Injection system; Filling/bleeding fuel system .
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐
necting and reconnecting battery .
Specified torque:
Component Nm
Fuel tank to body - M6 10
Fuel tank to body - M8 25
♦ Renew bolts
1. Fuel 17
1.3 Emptying fuel tank

⇒ “1.3.1 Emptying fuel tank when fuel pump is intact”,
page 18 .
⇒ “1.3.2 Emptying fuel tank if more than 3/4 full, engine codes
CDLG, CAVB, CAVC, CAVD, CBZA, CBZB, CTHD, CTKA”, page
21
⇒ “1.3.3 Emptying fuel tank if more than 3/4 full, CBTA, CBUA”,
page 23
⇒ “1.3.4 Emptying fuel tank if it is less than 3/4 full”, page 25
1.3.1 Emptying fuel tank when fuel pump is intact
Caution
Secure earth wire of fuel extractor to a bare metal part of the

body.
To extract E 85 fuel, use only fuel extractor - VAS 5190 A- .
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.
Caution
Fuel supply line is pressurised. 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 release pressure by carefully pulling hose
off connection.
Connect fuel extractor earth wire to earth.
Note

joined.
⇒ page 38 .

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

connectors ⇒ page 38 .
– Collect escaping fuel with a cleaning cloth.
1. Fuel 19
– Connect fuel extractor - VAS 5190- with adapter for fuel ex‐
tractor - VAS 5190 /3- to fuel supply line.
Caution

body.

ual seats .
– If fuel pump control unit - J538- -2- is fitted, remove from cover
-1-.
– Unclip cover -1- for flange at retaining tabs -arrows-, using re‐
moval wedge - 3409- .

– 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 fuel tank flap.

– Remove cap -arrow- from fuel filler neck.
– Operate remote control - V.A.G 1348/3A- and shut-off tap on
fuel extractor - VAS 5190- until fuel tank is empty.
Caution
Do not allow the fuel pump run »dry«.
1.3.2 Emptying fuel tank if more than 3/4 full,

engine codes CDLG, CAVB, CAVC,
Caution

body.

1. Fuel 21

– Remove cone piece -2- from shaft -1- of fuel extractor -
VAS 5190- .
– A mark -arrow- at distance -a- = 1180 mm from end of extrac‐
tion hose.
– Use insulating tape for this.

– Screw shaft -1- of fuel extractor - VAS 5190- onto fuel tank
filler neck.
– Push extraction hose into fuel tank until marking on hose
-arrow- coincides with shaft end.

Note
A ball valve -2- is located at the bottom of the filler neck in the fuel
tank -1-; 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.
The tank may be removed while containing remaining fuel.
♦ Draining fuel tank completely ⇒ page 25
1.3.3 Emptying fuel tank if more than 3/4 full,

CBTA, CBUA
Caution

body.


1. Fuel 23
– Remove cone piece -2- from shaft -1- of fuel extractor -

VAS 5190- .
– A mark -arrow- at distance -a- = 1500 mm from end of extrac‐
tion hose.
– Use insulating tape for this.

– Screw shaft -1- of fuel extractor - VAS 5190- onto fuel tank
filler neck.
– Push extraction hose into fuel tank until marking on hose
-arrow- coincides with shaft end.

– Push extraction hose of extraction unit into fuel tank until pre‐
viously attached marking -arrow- on hose coincides with filler
neck -2-.
– Drain fuel tank via filler neck as far as possible.
Note
♦ There is a flap -1- on the lower end of the fuel filler neck in the
fuel tank which must not be damaged by the extraction hose.
Therefore push hose into filler neck only as far as marking
-arrow-.
♦ If the extraction hose catches on the non-return valve when
being extracted, do not apply force to pull the extraction hose
out.
♦ In this case, remove the fuel delivery unit and open the non-
return valve manually. Ensure that your arm does not come
into contact with fuel.
– 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.
♦ Draining fuel tank completely ⇒ page 25
1.3.4 Emptying fuel tank if it is less than 3/4 full
Caution

body.
1. Fuel 25

equipment required

♦ Special wrench - T10202-
♦ Torque wrench - V.A.G 1332-
Note

joined.
⇒ page 38 .



ual seats .
-1-.
WARNING

off connection.
– Unlock and pull fuel line -1- and -2- off flange. Separate plug-
in connectors ⇒ page 38 .
1. Fuel 27
– Open locking ring using wrench - T10202- .
Caution
Do not cant key - T10202- and press against locking ring firmly.
If the key slips off, the fuel delivery unit can be damaged.
– Carefully lift flange of fuel delivery unit.

– Insert suction hose of fuel extractor - VAS 5190- as far as
possible into fuel tank.
– Extract fuel.
If fuel tank needs only to be emptied, install fuel delivery unit
again. ⇒ page 31 .
Specified torque
♦ ⇒ “2.1 Assembly overview - fuel delivery unit/fuel gauge send‐
er”, page 29
♦ ⇒ General body repairs, interior; Rep. gr. 72 ; Rear seat;
Removing and installing bench seat / individual seats
♦ ⇒ Electrical system; Rep. gr. 27 ; Battery; Disconnecting and
connecting battery
♦ ⇒ Auxiliary heating; Rep. gr. 82 ; Auxiliary/supplementary
heating; Assembly overview - auxiliary/supplementary heat‐
ing, interior

2 Fuel delivery unit, fuel gauge sender

⇒ “2.1 Assembly overview - fuel delivery unit/fuel gauge sender”,
page 29
⇒ “2.2 Removing and installing fuel delivery unit, fuel gauge send‐
er”, page 31
⇒ “2.3 Removing and installing fuel gauge sender G ”,
page 36
2.1 Assembly overview - fuel delivery unit/fuel gauge sender
Note
♦ Plug-in connectors for fuel lines must engage »audibly« when joined.
♦ Note colour assignment when installing the plug-in connectors ⇒ page 38 .
♦ Hose connections are secured with either spring-type or clamp-type clips.
♦ Renew clamp-type clips with spring-type clips.
♦ Fuel hoses on engine must be secured with spring-type clips only. The use of crimp-type or screw-type clips
is not permissible.
♦ Hose clip pliers - VAS 6340- are recommended to install spring-type clips.
2. Fuel delivery unit, fuel gauge sender 29

1 - Locking ring
❑ 110 Nm
2 - Supply line
❑ black
❑ Clipped onto side of fuel
tank.
❑ Ensure firm seating
3 - Return line
❑ blue
❑ Clipped onto side of fuel
tank.
❑ Ensure firm seating
4 - Flange
❑ For fuel delivery unit.
❑ Note installation posi‐
tion of flange on fuel
tank ⇒ page 30 .
5 - Fuel gauge sender - G-
⇒ page 36
⇒ page 31
❑ With fuel system pres‐
surisation pump - G6-
❑ Checking fuel pump
⇒ page 63 .
7 - Seal
❑ Renew
❑ When installing, fit dry in
fuel tank opening.
❑ Moisten with fuel only when installing flange.
Installation position of flange

– Push flange downwards against spring force and move flange
into installation position.
tank.

2.2 Removing and installing fuel delivery

unit, fuel gauge sender
Note
♦ After removing fuel delivery unit, check fuel tank for heavy
soiling and clean if necessary.
joined.
⇒ page 38 .
♦ Hose connections are secured with either spring-type or
clamp-type clips.
♦ Renew clamp-type clips with spring-type clips.
♦ Fuel hoses on engine must be secured with spring-type clips
only. The use of crimp-type or screw-type clips is not permis‐
sible.
♦ Hose clip pliers - VAS 6340- are recommended to install
spring-type clips.

♦ Special wrench - T10202-
♦ Torque wrench (40 … 200 Nm) - V.A.G 1332-

Removing
Caution
Condition:
• 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.
Note
Assembly overview - fuel system ⇒ page 6 .

– Drain fuel tank with fuel extractor - VAS 5190- ⇒ page 18 .
– Disconnect battery earth strap ⇒ Electrical system; Rep. gr.
27 ; Battery; Disconnecting and connecting battery .
Caution
There is a danger of damage to the electronic components

when disconnecting the battery.
♦ Observe the necessary measures when disconnecting the
battery.
– Remove rear bench seat ⇒ General body repairs, interior;

Rep. gr. 72 ; Rear seats; Removing and installing bench seat /
individual seats .
-1-.

WARNING

off connection.
– Pull fuel lines -1- and -2- off the flange. Separate plug-in con‐
nectors ⇒ page 38 .
Note
On vehicles with auxiliary heater, the connector and the fuel line
of the metering pump - V54- must also be disconnected.
– Open locking ring using wrench - T10202- and raise flange

slightly.
Caution

– Pull fuel delivery unit -1- and oil seal out of opening in fuel tank.
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:
Note
♦ Make sure all components are mounted in the correct position.

♦ Observe installation position of fuel feed line to auxiliary heater
⇒ Auxiliary heater; Rep. gr. 82 ; Fuel supply; Installation
overview - fuel supply .
joined.
⇒ page 38 .
– Renew seal.
– Insert seal for fuel delivery unit dry into opening of fuel tank.
– Coat inner side of seal with fuel.
– When inserting fuel delivery unit, ensure that fuel gauge send‐
er is not bent.
– Push flange downwards against spring force and move flange

into installation position.
tank.

– Tighten locking ring using wrench - T10202- .
Caution
– Reconnect supply line-1- (black).

– Reconnect fuel return line -2- (blue or blue marking).
– Reconnect connector -arrow-.

– Ensure push-fit couplings and electrical connectors are se‐
cured properly by pulling.
Further assembly is performed in the reverse order of removal.
During this procedure, observe the following:
♦ Observe installation position of fuel feed line to auxiliary heater

⇒ Auxiliary heater; Rep. gr. 82 ; Auxiliary heater; Assembly
overview - inner auxiliary heater .
♦ The -arrow- on the cover points forwards.
Specified torque
♦ ⇒ “2.1 Assembly overview - fuel delivery unit/fuel gauge send‐
er”, page 29
♦ ⇒ General body repairs, interior; Rep. gr. 72 ; Rear seat;
Removing and installing bench seat / individual seats
♦ ⇒ Electrical system; Rep. gr. 27 ; Battery; Disconnecting and
connecting battery
♦ ⇒ Auxiliary heating; Rep. gr. 82 ; Auxiliary/supplementary
heating; Assembly overview - auxiliary/supplementary heat‐
ing, interior

2.3 Removing and installing fuel gauge

sender - G-
Note
♦ Gradual introduction of fuel delivery units with modified fuel

gauge senders - G- .
♦ After removing the fuel delivery unit, check which version of
fuel gauge sender - G- is fitted.
– Remove fuel delivery unit ⇒ page 31 .

Version 1
– Note colour assignment of cables for re-installation.
– Release connector lugs on lines -3- and -4- and pull off.
– Lift retaining tabs -1- and -2- using a screwdriver and pull off
fuel gauge sender downwards -arrows-.
Installing:
– Note colour assignment.
– Check connectors are secured properly by pulling.
– Insert fuel sender into guides on fuel delivery unit and press
upwards until it engages.
Version 2:
– Release connectors -arrows- and pull off electrical lines -1-
through -3-.
– Lift securing tabs -4- and -5- using a screwdriver, and pull off
fuel gauge sender - G- downwards -arrow-.
Installing:
– Insert fuel gauge sender - G- into guides on fuel delivery unit
and press upwards until it engages.
– Connect connector.
Version 3:
– 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.

– Pull off electrical connectors -1- through -3-.
– Then bend back locking lugs of connectors.
Installing:
– Connect connectors -1- through -3-.
– Insert fuel gauge sender - G- into guide on fuel delivery unit
and press down until it engages.
Continued for all vehicles
– Install fuel delivery unit ⇒ page 31 .

3 Plug-in connectors
⇒ “3.1 Separating plug-in connectors”, page 38
3.1 Separating plug-in connectors

♦ -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 con‐
nector or the release button is coloured.
Plug-in connector Colour code on plug-in connec‐

tor
Fuel supply black
Fuel return line blue
Breather white
Vacuum green
WARNING

off connection.
Version 1
Plug-in connector with release buttons -arrows- on right and left
Open

It is necessary to counterhold the separating point for fuel -1-.

– Insert -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 release buttons and pull plug-in connector -1- off fuel
line -2- in -direction of arrow B-.
Note colour assignment during installation ⇒ page 38 .
– Ensure plug-in connector is secured properly by pulling it.
Version 2
Plug-in connector with pull-release mechanism -arrow-
Open
3. Plug-in connectors 39
– 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-.
Version 3
Plug-in connector with front button -arrow-
Open
– Press release tab -arrow- and detach push-fit connector.
Note colour assignment during installation ⇒ page 38 :
Version 4
Plug-in connector with release buttons -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.
Version 5
Open
– Press release buttons -arrows- and pull off plug-in connector.

Version 6
Open
– Push plug-in connector in -direction of arrow-.
– Press and hold release buttons -arrows-.
– Pull off plug-in connector.
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-.
Plug-in connectors for fuel lines must engage »audibly« when
joined.
3. Plug-in connectors 41
4 Fuel filter
⇒ “4.1 Assembly overview - fuel filter”, page 42
⇒ “4.2 Removing and installing fuel filter”, page 42
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 fuel pressure limit‐
ing valve
❑ Direction of flow is
marked with arrows
❑ Do not interchange con‐
nections.
❑ Installation position: pin
on filter housing must
engage in notch of guide
in filter bracket
⇒ page 43 .
⇒ page 42
2 - Fuel supply line
❑ black
❑ From fuel tank
❑ Detach ⇒ page 38
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

♦ Drip tray
Removing

– Place tray under fuel filter.
WARNING

off connection.
– Pull off fuel lines -1-, -2- and -3-. Separate plug-in connectors
⇒ page 38 .
– Unscrew bolt -4-.
– Remove fuel filter.
Installing
Installation is carried out in the reverse order. When installing,
note the following:
Installation position:
• Specified torque ⇒ page 42 .
• 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.
4. Fuel filter 43
5 Activated charcoal filter system

⇒ “5.1 Assembly overview - activated charcoal filter system”, page
44
⇒ “5.2 Removing and installing activated charcoal filter, engine
codes CBTA, CBUA”, page 47
⇒ “5.3 Checking fuel tank breather, engine codes CDLG, CAVB,
CAVC, CAVD, CBZA, CBZB, CTHD, CTKA”, page 48
⇒ “5.4 Checking fuel system for leaks, engine codes CBTA,
CBUA”, page 50
⇒ “5.5 Schematic diagram of activated charcoal filter system, en‐
gine codes CBTA, CBUA”, page 57
⇒ “5.6 Removing and installing fuel system diagnostic pump
(CBTA, CBUA)”, page 59
5.1 Assembly overview - activated charcoal

filter system
⇒ “5.1.1 Assembly overview - activated charcoal filter, engine co‐
des CDLG, CAVB, CAVC, CAVD, CBZA, CBZB, CTHD,CTKA”,
page 44
⇒ “5.1.2 Assembly overview - activated charcoal filter, engine co‐
des CBTA, CBUA”, page 46
5.1.1 Assembly overview - activated charcoal filter, engine codes CDLG, CAVB,
CAVC, CAVD, CBZA, CBZB, CTHD,CTKA

1 - Activated charcoal filter

❑ Location: on right in en‐
gine compartment.
2 - Pressure retention valve
with connecting hose
3 - Connection hose
ing.
❑ From fuel tank
4 - Nut
❑ 10 Nm
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 - Connection hose
❑ To intake manifold
ing.
7 - Holder
❑ For activated charcoal
filter.
8 - Vent hole
5. Activated charcoal filter system 45

5.1.2 Assembly overview - activated charcoal filter, engine codes CBTA, CBUA
1 - Activated carbon filter

❑ Only installed with en‐
gine code CBUA
2 - Bolt
❑ 8 Nm
3 - Bush
❑ Location: down in spare
wheel well
⇒ page 47
5 - Nut
❑ 6 Nm
6 - Holder
7 - Support
8 - Holder
9 - Bolt
❑ 4 Nm
10 - Rubber grommet
11 - Washer
12 - Bolt
❑ 8 Nm
13 - Breather line
❑ To engine
14 - Fuel system diagnostic
pump - V144-
❑ Fitting location: In rear
right wheel housing be‐
neath liner
❑ Checking ⇒ Vehicle diagnostic tester
15 - Bolt
❑ 4 Nm
16 - Connection hose
17 - Clip
18 - Air filter
❑ For fuel system diagnosis pump - V144- .
❑ No maintenance specification
19 - Holder
20 - Connecting pipe
❑ Clip onto bracket.
❑ Press release tab on connector to disconnect.
21 - Breather line
❑ To filler neck on fuel tank

22 - Breather line
23 - Breather line
❑ To activated charcoal filter solenoid valve 1 - N80-
5.2 Removing and installing activated char‐

coal filter, engine codes CBTA, CBUA
♦ Engine and gearbox jack - V.A.G 1383 A-
Removing:
– Remove centre silencer and rear silencer ⇒ Rep. gr. 26 ;
Exhaust system/silencer; Assembly overview - silencers .
– Remove heat shield -arrows-.
– Place engine and gearbox jack - V.A.G 1383 A- under rear
axle to support it.
– Loosen securing bolts of rear axle -arrows- and back them out
approx. 20 mm.
– Lower rear axle slowly with engine and gearbox jack -
V.A.G 1383 A- .

– Pull off breather lines -A- by pressing in release button.

– Remove bolts -B-.
– Release retaining tab -A- using a screwdriver.
– Turn activated charcoal filter approx. 90° to the right -B-.
– Remove activated charcoal filter.

Installing:
note the following:
– Push on breather lines until they engage audibly.
– Install rear axle ⇒ Running gear; Rep. gr. 42 .
Specified torque
♦ ⇒ page 46
5.3 Checking fuel tank breather, engine co‐

des CDLG, CAVB, CAVC, CAVD,
♦ Hand operated vacuum pump - VAS 6213-
♦ Pressure gauge - VAS 6550-

♦ Connecting nipple - VAS 6550/3-1-
Test specification:
• Ignition must be switched off.
Test sequence
– Pull off bleeder line -1-. Separate plug-in connectors
⇒ page 38 .
– Connect hand vacuum pump - VAS 6213- to breather line

leading to activated charcoal filter as shown.
– Connect connecting nipple - VAS 6550/3-1- to breather line so
that nipple engages.
– Connect hand vacuum pump - VAS 6213- to connecting nipple
- VAS 6550/3-1- using a standard hose -A-.
– Move slide ring -1- on hand vacuum pump - VAS 6213- to po‐
sition -B- for “pressure”.
Checking breather connection on activated charcoal filter
– Also clamp off hose between activated charcoal filter and ac‐
tivated charcoal filter solenoid valve 1 - N80-
⇒ Item 5 (page 45) .
– Using hand-operated vacuum pump - VAS 6213- , build up
pressure of approx. 0.1 bar.
• If pressure does »not« build up:
– Breather connection is OK.
If pressure builds up:
– Check breather hole on activated charcoal filter
⇒ Item 8 (page 45) for soiling and clean if necessary.

Checking activated charcoal filter for leaks

– Also clamp off hose between activated charcoal filter and ac‐
tivated charcoal filter solenoid valve 1 - N80-
⇒ Item 5 (page 45) .
– Seal breather hole -arrow- and operate hand vacuum pump -
VAS 6213- again several times.
If pressure does not build up:
– Check lines and connections on activated charcoal filter with
commercially available leak detection spray.
– If no fault is found: renew activated charcoal filter ⇒ page 44 .
Checking activated charcoal filter system solenoid valve 1 - N80-

for leaks
• Hose between activated charcoal filter and activated charcoal
filter solenoid valve 1 - N80- ⇒ Item 5 (page 45) must not be
closed.
– Seal breather hole -arrow-.
If pressure does not build up:
– Check hose between activated charcoal filter and activated
charcoal filter solenoid valve 1 - N80- with commercially avail‐
able leak detection spray.
– If no fault is found, renew activated charcoal filter solenoid
valve 1 - N80- .
5.4 Checking fuel system for leaks, engine

codes CBTA, CBUA
⇒ “5.4.1 Checking fuel system for leaks”, page 50
⇒ “5.4.2 Leak detection in fuel system”, page 54
⇒ “5.4.3 Schematic overview of activated charcoal filter system”,
page 55
⇒ “5.4.4 Checking vacuum supply of fuel system diagnostic
pump”, page 56
5.4.1 Checking fuel system for leaks

♦ Fuel system tester (so-called smoke tester) - KLI 9210-
♦ Adapter hose - KLI 9210/55-1-
♦ Vehicle diagnostic tester

♦ Hose clamps to 25 mm - 3094-
The plug-in connectors for fuel, vacuum and breather lines are
colour coded. There is either a coloured dot on the plug-in con‐
nector or the release button is coloured.
Plug-in connector Colour code on plug-in connec‐
tor
Fuel supply black
Fuel return line blue
Breather white
Vacuum green
Test specification:
• A leak has been detected by the fuel system diagnostic pump
- V144- .
• Guided fault finding has been performed with the vehicle di‐
agnostic tester .
Preparation of fuel system tester - KLI 9210- :
Note
The fuel system tester - KLI 9210- may differ in appearance de‐
pending on the version.
– Check fuel system tester - KLI 9210- to ensure that there is

enough fluid in smoke generator.
– Set valve -D- to “Hold”.
– Open nitrogen bottle -H-.
– Connect test hose -G- to self-test connection -B-.
– Set valve -D- to “Test”.
– Regulate pressure to 10 in. H2O (25 mbar) with pressure re‐
ducer -J-.
– Now pressure must be maintained for at least 2 minutes.
Check tester if pressure is not maintained.
Checking fuel system for leaks:

– Connect adapter hose - KLI 9210/55-1- to breather line -A-

(colour code: white).
– Connect test hose -G- of fuel system tester - KLI 9210- to

adapter hose - KLI 9210/55-1- .
– Connect vehicle diagnostic tester to vehicle.

– Start engine and run at idling speed.
– On vehicle diagnostic tester , select operating mode Guided
functions .
– Select guided function “Check tank ventilation system for

leaks”.
– Start test.
– Observe pressure gauge - KLI 9210- while test is running.
• Fuel system diagnostic pump - V144- must pump up pressure
in fuel system to at least 7 in. H2O (18 mbar).
The minimum pressure was not reached, but the available pres‐
sure does not drop.
– Switch ignition off and perform pressure retention test
⇒ page 53 .
– If no pressure drop can be detected, check vacuum supply for
fuel system diagnostic pump - V144- ⇒ page 56 .
The minimum pressure was not reached and the available pres‐
sure drops immediately:

– Clamp off hose to activated charcoal filter solenoid valve 1 -

N80- using hose clamps, up to Ø 25 mm - 3094- -arrow-.
– Repeat check. If the minimum pressure is reached now, renew
activated charcoal filter solenoid valve 1 - N80- .
If the minimum pressure was again not reached and the available
pressure drops immediately:
– There is a leak in the fuel system. Carry out “leak detection
test in fuel system” ⇒ page 54 .
If the minimum pressure is reached, switch the ignition off.
The valve in the fuel system diagnostic pump - V144- closes and
the pressure is retained.
– Observe pressure gauge:
If the pressure does not drop at first, perform a pressure retention
test to localise a possible tiny leak ⇒ page 53 .
If pressure drops, clamp off hose to activated charcoal filter sol‐

enoid valve 1 - N80- using hose clamps, up to Ø 25 mm - 3094-
-arrow-.
– If the pressure does not drop again, renew activated charcoal
filter solenoid valve 1 - N80- .
If pressure still drops, perform “leak detection in fuel system” test
⇒ page 54 .
Pressure retention test
– Set valve -D- to “Test”. Increase existing pressure to 10 in.

H2O (25 mbar).
– Observe pressure gauge -C- and flow meter -E-. When flow
rate decreases and pressure increases to 10 in. H2O
(25 mbar), fuel system is filled.
Note
Depending on the filling level of the fuel tank, this process can
take up to 3 minutes.
– Once pressure has stabilised, set valve -D- to “Hold”.

• After 5 minutes, pressure must not drop below 8 in. H2O (20
mbar).
If the pressure is not held for at least 5 minutes, localise leak as
follows:

– First check activated charcoal filter solenoid valve 1 - N80- for

leaks. To do this, clamp off hose to activated charcoal filter
solenoid valve 1 - N80- using hose clamps, up to Ø 25 mm -
3094- -arrow-.
– Repeat pressure test; to do this, set valve -D- to “Test” again.

– Observe pressure gauge and flow meter. When flow rate de‐
creases and pressure increases to 10 in. H2O (25 mbar), fuel
system is filled.
– If the pressure does not drop again, renew activated charcoal
filter solenoid valve 1 - N80- .
If pressure still drops, perform “leak detection in fuel system” test
⇒ page 54 .
After completing work with vehicle diagnostic tester , perform gui‐
ded function “Checking fuel tank ventilation system for leaks”.
5.4.2 Leak detection in fuel system

Test specification:
• Procedure for “checking fuel system for leaks” has been com‐
pleted ⇒ page 50 .
• Fuel system tester - KLI 9210- is connected to vehicle via
adapter hose - KLI 9210/55-1- .
– Connect fuel system tester - KLI 9210- to vehicle battery.
– Remove rear right wheel housing liner.

– Clamp off hose between fuel system diagnostic pump - V144-

and air filter -arrow-.
– Set valve -D- to “Test”.

– Observe pressure gauge -C- and flow meter -E-. When flow
rate decreases and pressure increases to 10 in. H2O
(25 mbar), fuel system is filled.
• After 5 minutes, pressure must not drop below 8 in. H2O (20
mbar).
– If the pressure no longer drops, renew fuel system diagnostic
pump - V144- .
If the pressure is not held for at least 5 minutes or does not build
up, localise leak as follows:
– Fill fuel system with smoke.
– To do this, set valve -D- to “Test” again.
– While fuel system is being filled, depress button -I- for smoke
generator for approx. one minute.
The fuel system is now pressurised and filled with smoke.
– Check all pipes and hoses of fuel system for escaping smoke.
Also check fuel tank filler cap.
Note
♦ Illuminate all components and hoses with a powerful light. This

will make the smoke easier to detect.
♦ For leak detection in accessible areas, use ultrasonic tester or
commercially available leak-detecting spray.
♦ Depending on how long fault finding takes, it may be neces‐
sary to press the smoke generator button from time to time.
This ensures that sufficient smoke is present in the fuel sys‐
tem.
♦ To inspect flanges for fuel pump and fuel filter, assembly
opening in vehicle interior must be opened.
– Renew leaking hoses or components.

After completing work with vehicle diagnostic tester , perform gui‐
ded function “Checking fuel tank ventilation system for leaks”.
5.4.3 Schematic overview of activated charcoal filter system


2 - Location of adapter hose -
KLI 9210/55-1-
❑ For leak detection in fuel
system
4 - Breather line
❑ Throttle valve module -
J338-
5 - Solenoid valve
❑ For fuel system diagno‐
sis pump - V144- .
6 - Vacuum line
❑ To intake manifold
7 - Air filter
❑ For fuel system diagno‐
sis pump - V144- .
pump - V144-
9 - Fuel
10 - Cap
5.4.4 Checking vacuum supply of fuel system

diagnostic pump
♦ Turbocharger tester - V.A.G 1397A-
♦ T-piece - 251 201 346-

♦ Hose ∅ 6 mm

Note
Fitting location of fuel system diagnosis pump - V144- : rear right

wheel housing under wheel housing liner.

– Pull vacuum hose -1- off fuel system diagnostic pump - V144- .
– Connect turbocharger tester - V.A.G 1397A- with T-piece and
6 mm hose between vacuum line -1- and fuel system diag‐
nostic pump - V144- -2-.
– Switch on measuring range I (absolute pressure measure‐
ment).
– Connect vehicle diagnostic tester and start engine.
– On vehicle diagnostic tester , select operating mode Guided
functions .
– Select guided function “Check tank ventilation system for

leaks”.
– Activate test.
– Observe display on turbocharger tester - V.A.G 1397A- during
test.
• Pressure must pulsate and must remain at or below 0.7 bar
(absolute pressure) during test.
– If pressure exceeds 0.700 bar during test, vacuum supply is
too low: Check vacuum line to intake manifold for possible
kinks or blockages.
5.5 Schematic diagram of activated char‐

coal filter system, engine codes CBTA,
CBUA
⇒ “5.5.1 Schematic diagram of activated charcoal filter system,
engine codes CBTA, CBUA”, page 57
5.5.1 Schematic diagram of activated charcoal filter system, engine codes CBTA,
CBUA


pump - V144-
❑ Fitting location: In rear
right wheel housing be‐
neath liner
❑ Checking ⇒ Vehicle di‐
agnostic tester
⇒ page 47
2 - Connecting cable
❑ From fuel system diag‐
nostic pump - V144- to
activated charcoal filter.
❑ Clip onto bracket.
❑ Location: down in spare
wheel well
❑ A filter is also installed
with engine code CBUA
⇒ Item 1 (page 46)
⇒ page 47
4 - Separation point
❑ Rear right on fuel tank
5 - Throttle valve module -
J338-
⇒ Fuel preparation, in‐
jection; Rep. gr. 24
❑ Checking ⇒ Vehicle di‐
agnostic tester
7 - Vacuum line
❑ Connected to intake manifold
❑ Front right in engine compartment under coolant expansion tank
9 - Breather line
❑ white
❑ From activated charcoal filter to activated charcoal filter solenoid valve 1 - N80-
❑ Installation position: On right under vehicle
10 - Vacuum line
❑ green
❑ From engine to fuel system diagnostic pump - V144-
❑ Installation position: On right under vehicle
❑ Front right on fuel tank in vicinity of fuel filter
12 - Filler neck
13 - Breather line
❑ From filler neck to activated charcoal filter

14 - Air filter
❑ For fuel system diagnosis pump - V144- .
5.6 Removing and installing fuel system di‐

agnostic pump (CBTA, CBUA)
Removing:
– Detach vacuum line -1-.
– Release and pull off connector -2-.
– Press release button and pull off breather line -3-.
– Remove nuts -arrows-.
– Unhook diagnosis pump with bracket.
Installing:
note the following:
• The breather line -3- must engage audibly.
– Install rear right wheel housing liner ⇒ General body repairs,
exterior; Rep. gr. 66 ; Wheel housing liner; Removing and
installing wheel housing liner .
– Fit rear right wheel ⇒ Running gear, axles, steering; Rep. gr.
44 ; Wheels, tyres and alignment .
Specified torque
♦ ⇒ “5.1.2 Assembly overview - activated charcoal filter, engine
codes CBTA, CBUA”, page 46
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liner; Removing and installing wheel housing liner .
♦ ⇒ Running gear, axles, steering; Rep. gr. 44 ; Wheels, tyres;
Wheel change .

6 Accelerator pedal
⇒ “6.1 Assembly overview - accelerator mechanism”, page 60
⇒ “6.2 Removing and installing accelerator pedal module”,
page 60
6.1 Assembly overview - accelerator mechanism
1 - Connector
❑ Black, 6-pin.
2 - Accelerator position sender
- G79- and accelerator position
sender 2 - G185-
❑ Openings -A- for re‐
lease tool.
❑ Remove in order to re‐
move trim in driver foot‐
well.
accelerator pedal mod‐
ule ⇒ page 60
3 - Bolt
❑ 10 Nm
4 - Protective cap
6.2 Removing and installing accelerator

pedal module

♦ Release tool - T10238-
♦ Release tool - T10240- for right-hand drive vehicles
Removing
– Remove cover for steering column -arrows-.
– Lever cover cap -3- out with a screwdriver.

– Unscrew securing bolt -2-.
– Pull off connector -1-.
– Push release tool - T10238- to stop into intended holes as
shown in illustration.
6. Accelerator pedal 61
– Remove accelerator module.
Installing
– Push connector -2- onto accelerator module -5-.
– Push accelerator module onto retaining pins -5-.
– Insert centring pin -6- into hole in underbody.
– Secure accelerator module with bolt -2-.
– Fit cap -3-.
– Reinstall cover for steering column -arrows-.

– If the accelerator pedal module was replaced, adapt module
to engine control unit ⇒ vehicle diagnostic tester “Guided
functions”.
– If the accelerator pedal module was renewed on vehicles with
an automatic gearbox, the kick-down function must be reprog‐
rammed ⇒ Vehicle diagnostic tester “Guided functions”.
Specified torque:
♦ ⇒ “6.2 Removing and installing accelerator pedal module”,
page 60

7 Fuel pump
⇒ “7.1 Checking fuel pump”, page 63
7.1 Checking fuel pump

⇒ “7.1.1 Checking function and voltage supply, engine codes
CDLG, CAVB, CAVC, CAVD, CBZA, CBZB, CTHD, CTKA”, page
63
⇒ “7.1.2 Checking function and voltage supply, engine codes
CBTA, CBUA”, page 67
⇒ “7.1.3 Checking fuel pressure, engine codes CDLG, CAVB,
⇒ “7.1.4 Checking fuel pressure, engine codes CBTA, CBUA”,
page 75
⇒ “7.1.5 Checking holding pressure, engine codes CDLG, CAVB,
⇒ “7.1.6 Checking holding pressure, engine codes CBTA, CBUA”,
page 84
⇒ “7.1.7 Checking fuel pressure during vehicle operation, engine
code CDLG”, page 89
⇒ “7.1.8 Checking fuel delivery rate, engine codes CAVB, CAVC,
CAVD, CBZA, CBZB, CTHD, CTKA”, page 91
⇒ “7.1.9 Checking fuel delivery rate, engine code CDLG”,
page 99
⇒ “7.1.10 Checking fuel delivery rate, engine codes CBTA,
CBUA”, page 105
⇒ “7.1.11 Checking current draw, engine codes CDLG, CAVB,
⇒ “7.1.12 Checking current draw, engine codes CBTA, CBUA”,
page 115
7.1.1 Checking function and voltage supply,

engine codes CDLG, CAVB, CAVC,
7. Fuel pump 63
♦ Multimeter, e.g. hand-held multimeter - V.A.G 1526E-
♦ Auxiliary measuring set - V.A.G 1594C-

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

– Connect vehicle diagnostic tester -1- as follows:

– Connect diagnosis cable connector -2- to diagnostic connec‐
tion in driver footwell.
– Switch on ignition.
– Select Final control diagnosis for fuel pump on Vehicle
diagnostic tester .
The fuel pump must now run slowly up to maximum speed.
Note
♦ Function of fuel pump is checked using final control diagnosis.

♦ The fuel pump is now activated.
♦ The fuel pump runs very quietly.
♦ 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.
– Switch off ignition.

If fuel pump does not run:
ual seats .
– Ensure that connector on fuel pump control unit - J538- is fitted

securely by pulling connector without pressing catch. If con‐
nector was not inserted correctly, repeat functional check of
fuel pump ⇒ page 64 .
– Release and pull off connector from 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 .
• Specification: approx. battery voltage
Voltage supply not OK:
– Locate and eliminate open circuit referring to current flow di‐
agram ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
7. Fuel pump 65
Voltage supply OK:

– Unclip cover -1- for flange on right at retaining tabs using re‐
fuel delivery unit.
– Check that connector -arrow- is fitted securely by pulling con‐

nector without pressing catch.
– If connector was not inserted correctly, repeat functional check
of fuel pump ⇒ page 64 .
– Release and pull off connector -arrow-.
– 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.
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.
Vehicles with auxiliary heater:

– On vehicles with auxiliary heater, the connector and the fuel
line of the metering pump - V54- must also be disconnected.

Continued for all vehicles:

– Drain fuel tank ⇒ page 18 .
Caution
– Flange for fuel delivery unit.

– 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 31 .
7.1.2 Checking function and voltage supply,

engine codes CBTA, CBUA
7. Fuel pump 67
♦ Auxiliary measuring set - V.A.G 1594C-

Test conditions:
battery .
• Fuel pump relay - J17- OK ⇒ Vehicle diagnostic tester
• Fuse for fuel pump OK. Fuse assignment ⇒ Current flow dia‐
grams, Electrical fault finding and Fitting locations
Test sequence
– Connect vehicle diagnostic tester -1- as follows:
– Connect diagnosis cable connector -2- to diagnostic connec‐
tion in driver footwell.
– Switch on ignition.
– Select Final control diagnosis for fuel pump on Vehicle
diagnostic tester .
The fuel pump must now run slowly up to maximum speed.
Note
♦ Function of fuel pump is checked using final control diagnosis.

♦ The fuel pump is now activated.
♦ The fuel pump runs very quietly.
– Switch off ignition.

If fuel pump does not run:

ual seats .
– Unclip cover for sealing flange on right at retaining tabs
-arrows- using removal wedge - 3409- .

nector without pressing catch.
– If connector was not inserted correctly, repeat functional check
of fuel pump ⇒ page 68 .
– Connect test instrument/DSO adapter (5-pin) - VAS 5565- to

– Connect multimeter to cables -1- and -5- of test instrument
adapter/DSO (5-pin) - VAS 5565- .
– Repeat functional check of fuel pump ⇒ page 68 .
• Specification: approx. battery voltage.
Voltage supply not OK:
– Locate and eliminate open circuit referring to current flow di‐
agram ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
Voltage supply OK:
WARNING

Vehicles with auxiliary heater:

– On vehicles with auxiliary heater, the connector and the fuel
line of the metering pump - V54- must also be disconnected.
7. Fuel pump 69
Continued for all vehicles:

– Drain fuel tank ⇒ page 18 .
Caution
– 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 31 .
7.1.3 Checking fuel pressure, engine codes

CDLG, CAVB, CAVC, CAVD, CBZA,
CBZB, CTHD, CTKA

Test conditions
• Voltage supply OK.

– Pull off supply line -1-. Separate plug-in connectors

⇒ page 38 .
WARNING

– Connect hose - VAS 6550/2- to connection -A- of pressure

tester - VAS 6550- .
– Use hose - VAS 6550- to connect fuel line leading to fuel tank
with pressure tester - VAS 6550/2- .
– Connect hose - VAS 6550/1- to fuel supply line leading to en‐
gine.
– Connect hose - VAS 6550/1- to connection -B- of pressure
– Ensure plug-in connectors are secure properly by pulling.
– Ensure that drain tap -C- on pressure tester -1- is closed.

– Shut-off valves -A- and -B- on pressure tester -1- are open.
– Connect vehicle diagnostic tester
– Activate fuel pump with final control diagnosis under "Engine
electronics".
Note
♦ The fuel pump is now actuated to build up fuel pressure.

– Read off fuel pressure on pressure gauge.
Specification:
Engine code Specified fuel pressure in bar
CDLG, CAVB, CAVC, CAVD, 4.0 … 7.0 bar
CBZA, CBZB, CTHD,CTKA
If fuel pressure is OK, check holding pressure ⇒ page 79 .

If the specification is exceeded:
– Check return line between fuel filter and fuel pump for kinks
and blockages ⇒ page 6 .
If no fault is detected on fuel line:
7. Fuel pump 71
– Pressure limiting valve in fuel filter is defective. Renew fuel

filter ⇒ page 42 .
If specification is not obtained
Check fuel pressure before fuel filter by following this procedure:
Checking fuel pressure before fuel filter:
– Pull fuel supply line -arrow- off fuel filter. Separate plug-in con‐
WARNING

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

fuel supply line using hose - VAS 6550/1- and hose - VAS
6550/2- .


– Repeat final control diagnosis of fuel pump to build up fuel
pressure ⇒ page 71 .
If reading matches specification:
– Check fuel line between fuel filter and engine compartment for
restrictions (kinks) or blockages.
leaks and damage.
If no fault is detected:
– Fuel filter is blocked. Renew fuel filter ⇒ page 42 .
Proceed as follows to check fuel pressure at fuel delivery unit:
Checking fuel pressure on fuel delivery unit:
ual seats .
fuel delivery unit.
– Unclip right cover -1- at retaining tabs -arrows-, using removal

wedge - 3409- .
7. Fuel pump 73
– Pull fuel line -1- off flange. Separate plug-in connectors

⇒ page 38 .
WARNING


6550/2- .
– Connect hose - VAS 6550/2- between connection -A- of pres‐
sure tester - VAS 6550- and the fuel delivery unit -1-.
– Connect hose - VAS 6550/1- between connection -B- of pres‐
sure tester - VAS 6550- and the fuel supply line -2-.

– Check fuel lines for possible restrictions (kinks) or blockages.
– Check fuel line for leaks and damage.

– Remove fuel delivery unit and check for contamination
⇒ page 31 .
– Check that all hoses are connected -arrows-.
– Check fuel lines for leaks and damage.
If no fault is found:
– Fuel pump is defective; renew fuel delivery unit ⇒ page 31 .

7.1.4 Checking fuel pressure, engine codes

CBTA, CBUA

Test conditions
• Voltage supply OK.
⇒ page 38 .
WARNING

7. Fuel pump 75

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

– Connect vehicle diagnostic tester
– Activate fuel pump with final control diagnosis under "Engine
electronics".
Note

– Read off fuel pressure on pressure gauge.
Specification:
CBTA, CBUA 3.5 … 4.5 bar
If fuel pressure is OK, check holding pressure ⇒ page 79 .

If the specification is exceeded:
– Check return line between fuel filter and fuel pump for kinks
and blockages ⇒ page 6 .
If no fault is detected on fuel line:
Check fuel pressure before fuel filter by following this procedure:

Checking fuel pressure before fuel filter:

WARNING


6550/2- .

restrictions (kinks) or blockages.
leaks and damage.
– Fuel filter is blocked. Renew fuel filter ⇒ page 42 .
Proceed as follows to check fuel pressure at fuel delivery unit:
Checking fuel pressure on fuel delivery unit:
ual seats .
7. Fuel pump 77

wedge - 3409- .

⇒ page 38 .
WARNING


6550/2- .

– Check fuel line for leaks and damage.


– Remove fuel delivery unit and check for contamination
⇒ page 31 .
– Fuel pump is defective; renew fuel delivery unit ⇒ page 31 .
7.1.5 Checking holding pressure, engine co‐

des CDLG, CAVB, CAVC, CAVD,

Test conditions:
• Voltage supply OK ⇒ page 63 .
• Fuel pressure OK ⇒ page 70 .
7. Fuel pump 79
– Connect hose - VAS 6550/2- between fuel line from fuel tank
to shut-off tap -A- of pressure tester - VAS 6550- .
– Connect hose - VAS 6550/1- between fuel line leading to en‐
gine and shut-off tap -B- of pressure tester - VAS 6550- .
Test sequence
– Actuate fuel pump with final control diagnosis to build up fuel
pressure.
Note

– Read fuel pressure on pressure gauge and observe.

Specification:
CDLG, CAVB, ≥ 4.0
CAVC, CAVD,
CBZA, CBZB,
CTHD, CTKA
– 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 bar.
If the pressure drops:
– Check all fuel lines for leaks and damage.

pressure.
– 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 holding pressure on fuel filter ⇒ page 81 .
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-. Ac‐
tuate 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 on fuel filter:

WARNING

7. Fuel pump 81

6550/2- .

– Repeat holding pressure check ⇒ page 80 .
– After pressure has built up, close shut-off tap -A-.
– Observe pressure drop on pressure gauge. After 10 minutes,
If pressure no longer drops:
– Check fuel line leading to engine for leaks.
– Check fuel filter for leaks.
Proceed as follows to check holding pressure at fuel delivery unit:
Checking residual pressure on fuel delivery unit:
ual seats .
– Remove fuel pump control unit - J538- -2- from cover -1-.


wedge - 3409- .

⇒ page 38 .
WARNING


6550/2- .

– After pressure has built up, close cut-off tap -B-.
If the pressure does not drop:
– Check fuel line leading to fuel filter for leaks.
7. Fuel pump 83

– If pressure retention valve in fuel pump is defective; renew fuel
delivery unit ⇒ page 31 .
7.1.6 Checking holding pressure, engine co‐

des CBTA, CBUA

Test conditions:

– Connect hose - VAS 6550/2- between fuel line from fuel tank
to shut-off tap -A- of pressure tester - VAS 6550- .
– Connect hose - VAS 6550/1- between fuel line leading to en‐
gine and shut-off tap -B- of pressure tester - VAS 6550- .
Test sequence
pressure.
Note

– Read fuel pressure on pressure gauge and observe.

Specification:
CBTA, ≥ 3.5
CBUA
– End self-diagnosis, and switch off ignition.
• Observe pressure drop on pressure gauge. After 10 minutes,
– Check all fuel lines for leaks and damage.
7. Fuel pump 85
pressure.
– 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 holding pressure on fuel filter ⇒ page 86 .
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-. Ac‐
tuate 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 on fuel filter:

WARNING



6550/2- .

– After pressure has built up, close shut-off tap -A-.
pressure must not drop below 3.0 bar.
If pressure no longer drops:
– Check fuel line leading to engine for leaks.
– Check fuel filter for leaks.
Proceed as follows to check holding pressure at fuel delivery unit:
Checking residual pressure on fuel delivery unit:
ual seats .

wedge - 3409- .
7. Fuel pump 87

⇒ page 38 .
WARNING


6550/2- .

– After pressure has built up, close cut-off tap -B-.
pressure must not drop below 3.0 bar.
If the pressure does not drop:
– Check fuel line leading to fuel filter for leaks.

– If pressure retention valve in fuel pump is defective; renew fuel
delivery unit ⇒ page 31 .

7.1.7 Checking fuel pressure during vehicle

operation, engine code CDLG
Note
♦ If a complaint is made about the vehicle's performance, the

reason may be that the fuel pressure is too low. Faults in the
high-pressure section may also be caused by inadequate fuel
pressure in the low-pressure section. This check determines
the fuel pressure in the high-pressure and low-pressure sec‐
tions during a road test. Fuel pressure in the high-pressure
section is read from the engine control unit. The fuel pressure
in the low-pressure section is measured using pressure tester
- VAS 6550- and vehicle diagnostic tester .
♦ This test can be part of “Guided Fault Finding” if an entry has
been made in the event memory. However, it can also be star‐
ted in the vehicle diagnostic tester by means of “Functions and
component selection”.


♦ Connector cable - VAS 5051/66-
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.
7. Fuel pump 89
Test conditions:
battery .
• Fuel pump fuse OK ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations
• Check that connector is fitted securely by pulling connector
without pressing catch. If connector was not inserted correctly,
repeat functional check of fuel pump.
• Filling level in fuel tank above reserve.
Checking fuel pressure during vehicle operation:
ual seats .

wedge - 3409- .

– Pull off supply line -arrow-. Separate plug-in connectors

⇒ page 38 .
WARNING

– Using hose - VAS 6550- , connect pressure tester - VAS

6550/1- to fuel supply line.
– Connect pressure tester - VAS 6550- to fuel delivery unit using
hose - VAS 6550/2- .
– Connect connection lead - VAS 5051/66- to pressure tester -
VAS 6550- and to ⇒ Vehicle diagnostic tester.

– Switch on pressure tester - VAS 6550- .
Carry out fuel pressure test using “Guided fault finding”.
– Follow instructions on vehicle diagnostic tester .
WARNING
Test instruments and measuring equipment must always be

secured to the rear seat and operated by a second person from
this location.
7.1.8 Checking fuel delivery rate, engine codes CAVB, CAVC, CAVD, CBZA,
CBZB, CTHD, CTKA
7. Fuel pump 91

equipment required

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

♦ Measuring container, capacity: 3 litres
Note

Test conditions:
battery .
Test sequence
Checking fuel delivery rate in engine compartment:
individual seats .
7. Fuel pump 93

wedge - 3409- .

nector without pressing catch. The connector can cause a fault
if it has not been fitted correctly.

– 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 hand-held multimeter to
contacts -1- and -5- of adapters - VAS 5565- .


⇒ page 38 .
WARNING


– Connect hose - VAS 6550- between fuel line from fuel tank
and pressure tester - VAS 6550/2- .
– Connect pressure regulator valve - VAS 6550/4- to connection
-B- of pressure tester - VAS 6550- .
– Hold end of hose of pressure regulating valve - VAS 6550/4-
in measuring container.

– Press remote control - V.A.G 1348/3A- .
Note
The fuel system pressurisation pump - G6- will be actuated.
7. Fuel pump 95
– Set pressure of 4.0 bar on pressure regulating valve -arrow-

using adjuster wheel.
– 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.

– Open tank flap unit.
– Clean area around fuel filler neck.
– Unscrew cap from fuel filler neck -arrow-.
– Repeat fuel delivery rate check ⇒ page 93 .
– Check fuel tank breather ⇒ page 44 .
Check fuel delivery rate at fuel filter as follows:
Checking fuel delivery rate at fuel filter:

WARNING


– Connect pressure tester - VAS 6550- to fuel supply line -2- by

means of hose - VAS 6550/1- .

Note

any more.
at fuel pump.
– Check fuel line leading to engine for possible restrictions
(kinks) or blockages.
– Check fuel line leading to engine for leaks and damage.
– Renew fuel filter ⇒ page 42 .
Proceed as follows to check fuel delivery rate at fuel delivery unit:
7. Fuel pump 97
Checking fuel delivery rate on fuel delivery unit:

⇒ page 38 .
WARNING

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

to fuel delivery unit -1-.

Note


any more.
at fuel pump.

– Remove fuel delivery unit and check filter strainer for dirt.
– Check that all fuel delivery unit -1- hose connections
-arrows- are connected.
– Check current draw of fuel pump ⇒ page 113 .
If no fault was detected in the current draw:
– Renew fuel delivery unit ⇒ page 31 .
If fuel delivery rate has been attained, but nevertheless you sus‐
pect a fuel supply system fault (e.g. intermittent failure of fuel
supply system):
7.1.9 Checking fuel delivery rate, engine code CDLG
7. Fuel pump 99

equipment required


Note

Test conditions:
battery .
Test sequence
Checking fuel delivery rate, quick test for vehicles with engine
code CDLG:
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 achieved,
a 2nd measurement must be carried out at the flange of the
fuel delivery unit.
♦ When driving characteristic problems occur when the fuel tank
is a approx. 1/4 filled, then check fuel delivery rates with ap‐
prox. 1/4 filled tank or less.
– Connect vehicle diagnosis and service information system to

vehicle.
– Select Guided functions in vehicle diagnosis and service
information system .
– Carry out identification of vehicle.
– Select Engine .
– Select Checking fuel delivery rate, quick test .
– Follow instructions on vehicle diagnostic tester .
7. Fuel pump 101


– Check fuel delivery rate, repeat quick test ⇒ page 101 .

WARNING




Note

any more.
at fuel pump.

in chart.
Name of axis Unit
ning.
Reading example:
7. Fuel pump 103


⇒ page 38 .
WARNING



Note


any more.
at fuel pump.

supply system):
7.1.10 Checking fuel delivery rate, engine codes CBTA, CBUA
7. Fuel pump 105


equipment required


Note

Test conditions:
battery .
Test sequence
Checking fuel delivery rate in engine compartment:
individual seats .
wedge - 3409- .
7. Fuel pump 107



– 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 hand-held multimeter -
V.A.G 1526E- to contacts -1- and -5- of adapters - VAS 5565- .


⇒ page 38 .
WARNING


– Connect hose - VAS 6550- between fuel line from fuel tank
and pressure tester - VAS 6550/2- .

Note
7. Fuel pump 109


any more.
at fuel pump.

in chart.
Name of axis Unit
ning.
Reading example:

– Repeat fuel delivery rate check ⇒ page 93 .

WARNING




Note

any more.
at fuel pump.
7. Fuel pump 111


⇒ page 38 .
WARNING



Note


any more.
at fuel pump.

supply system):
7.1.11 Checking current draw, engine codes

CDLG, CAVB, CAVC, CAVD, CBZA,
CBZB, CTHD, CTKA
7. Fuel pump 113

♦ Pick-up clamp e.g. pick-up clamp - V.A.G 1526B/2-

Note

joined.
⇒ page 38 .

ual seats .
fuel delivery unit.

– To do this, unclip cover -1- for flange at retaining tabs

-arrows-, using removal wedge - 3409- .

– Release and pull off connector.

– 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.
– Measure current draw of fuel pump.
• Specification: max. 9 amps
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:

– Remove fuel delivery unit ⇒ page 31 and check for contami‐
nation.
– Check fuel pressure ⇒ page 70 .
7.1.12 Checking current draw, engine codes

CBTA, CBUA
7. Fuel pump 115

♦ Pick-up clamp e.g. pick-up clamp - V.A.G 1526B/2-

Note

joined.
⇒ page 38 .

ual seats .

– To do this, unclip cover -1- for flange at retaining tabs

-arrows-, using removal wedge - 3409- .

– Release and pull off connector.

– 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.
– Measure current draw of fuel pump.
• Specification: max. 9 amps
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:

– Remove fuel delivery unit ⇒ page 31 and check for contami‐
nation.
– Check fuel pressure ⇒ page 70 .
7. Fuel pump 117

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Service

Service Department. Technical Information

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Codes CDLG CBTA CBUA CTHD, CTKA

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

2.1 Safety regulations for working on fuel

Observe the following points during all installation work, in par‐

When removing and installing fuel gauge sender - G- or fuel pump

2 Rep. gr.00 - Technical data

Fuel system is under pressure! Wear eye protection and pro‐

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

To prevent injuries to persons and/or damage to the injection and

2.2 Safety precautions for when using test

Risk of accidents due to distraction and inadequate securing

2.3 Safety measures when working on ve‐

Risk of injury due to automatic start of engine in vehicles with

4 Rep. gr.00 - Technical data

3 General repair instructions

3.1 Rules for cleanliness

3. General repair instructions 5

20 – Fuel supply system

1.1 Assembly overview - fuel tank

6 Rep. gr.20 - Fuel supply system

Installation position of fuel delivery unit

1.1.2 Assembly overview - fuel tank, engine codes CBTA, CBUA

8 Rep. gr.20 - Fuel supply system

Installation position of fuel delivery unit

♦ -Arrow- points in direction of travel.

1.2 Removing and installing fuel tank

1.2.1 Removing and installing fuel tank, en‐

♦ Engine and gearbox jack - V.A.G 1383 A-

Removing fuel tank

10 Rep. gr.20 - Fuel supply system

– Unclip cover -1- at retaining tabs -arrows-, using removal

– Pull off connector -arrow-.

– Remove rear right wheel ⇒ Running gear, axles, steering;

– Loosen clamping sleeve -arrows-.

– Remove rear cross member for underbody. To do this, un‐

The aid of a 2nd mechanic is required to remove the rear part of

– Remove centre silencer and rear silencer ⇒ Rep. gr. 26 ;

– Unscrew bolts -1- and -3-.

12 Rep. gr.20 - Fuel supply system

– Unscrew bolts -2- and -4-.

The aid of a second mechanic is required to remove the fuel tank.

– Lower fuel tank and guide it out of the body structure.

– Slowly raise fuel tank into installation position.

♦ Note installation position of earth connection.

– Note installation position of earth connection.

Risk of explosion due to electrostatic discharge.

– Fill fuel tank with at least 5 litres of fuel.

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

1.2.2 Removing and installing fuel tank, en‐

14 Rep. gr.20 - Fuel supply system

♦ Torque wrench - V.A.G 1331-

Drain fuel tank with fuel extractor - VAS 5190- ⇒ page 18 .

– Note safety precautions ⇒ page 2 .

– Detach connector -1- from fuel delivery unit.

– Disconnect connectors -1- and -2-.

– Unclip ABS line -A- from retainer -arrows-.