CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...

4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

20 – Fuel supply system

1 Safety precautions
Safety precautions when working on fuel supply system
⇒ page 272 .

1.1 Safety regulations for working on fuel

supply

WARNING

♦ 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

cardiagn.com
would otherwise be activated when the driver's door is opened.
Use the following options to interrupt the power supply:
♦ Disconnect battery
Or
♦ Removing fuse for fuel pump control unit - J538-
Or
♦ Pull off connector from fuel delivery unit flange or fuel
pump control unit - J538-

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Observe the following points during all thinstallation
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♦ Route all the various lines and electrical wiring so that they
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are in their original positions.

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♦ Ensure that there is sufficient clearance to all moving or

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

urposes, in part or in wh

ignition system, the following must be observed:

t to the co

♦ Do not touch or pull off ignition coils with output stage when
engine is running or turning at starter speed.
rrectne

♦ Switch off ignition before connecting or disconnecting injection

and ignition system wiring as well as test instrument cables.
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When removing and installing fuel gauge sender or fuel pump

inform

(fuel delivery unit) from a full or partly full fuel tank, observe the
mer

following:
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♦ Before starting work, the extraction hose of a switched-on ex‐

c

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haust gas extraction system must be laid near to the assembly

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opening of the fuel tank. This draws away the fuel fumes that
iv

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escape. If no exhaust gas extraction system is available, a ra‐

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dial fan with a displacement greater than 15 m3/h can be used

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272 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!

Note the following if testers and measuring instruments have to
be used during a road test: n AG. Volkswagen A ge G do
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♦ Test instruments and measuring equipment by
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must always be ot g
ua
secured to the rear seat and operated
ir se
d by a second person from ran
tee
this location. ut
ho or
a ac
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♦ If test and measuring instruments are operated from front pas‐

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senger seat and the vehicle is involved in an accident, there

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is a possibility that the person sitting in this seat may receive
itte

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serious injuries when the airbag is triggered.

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urposes, in part or in wh

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1. Safety precautions 273

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

2 Rules for cleanliness

When working on the fuel supply and injection system, pay careful
attention to the following “5 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).
♦ If system is open: do not use compressed air if possible. Try
not to move the vehicle.

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274 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

3 Fuel tank (Passat, CC)

Safety precautions when working on fuel supply system
⇒ page 272 .
Comply with rules for cleanliness ⇒ page 274 .
Assembly overview - fuel tank (engine codes BZB, CAWA,
CAWB, CGYA, CCZA, CCZB, CDAA, CDAB) ⇒ page 275 .
Assembly overview - fuel tank (engine codes CBFA, CCTA,
CCTB) ⇒ page 276 .
Drain fuel tank ⇒ page 277 .
Removing and installing fuel tank ⇒ page 281 .

3.1 Assembly overview - fuel tank (engine codes BZB, CAWA, CAWB, CGYA,
CCZA, CCZB, CDAA, CDAB)

1 - Fuel line
❑ Ensure firm seating.

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❑ Clipped onto fuel tank.
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3 - Bolt, 1.5 Nm s au ac
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4 - Tank flap unit

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❑ With rubber cup.

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❑ Removing and installing ab

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exterior; Rep. gr. 55 ;

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Tank flap unit; Remov‐

spec
urposes, in part or in wh

ing and installing fuel

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tank flap unit .

5 - Breather hose
rrectne

❑ Clipped onto fuel tank.

❑ Ensure firm seating.
ss

6 - Earth connection
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❑ Ensure firm seating.

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7 - Fuel tank
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❑ Emptying ⇒ page 277

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❑ Removing and installing

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⇒ page 281
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11 - 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 ⇒ ETKA (Electronic parts catalogue) .
12 - Sealing ring
❑ Renew
❑ When installing, fit dry in fuel tank opening.

3. Fuel tank (Passat, CC) 275

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017
❑ Moisten with fuel only when installing flange.
13 - Fuel delivery unit
❑ Removing and installing ⇒ page 320
❑ Checking fuel pump ⇒ page 325 .
❑ Removing and installing fuel gauge sender - G- ⇒ page 324
❑ Clean strainer if soiled
14 - Suction-jet pump
15 - Flange with fuel filter
❑ With 6.2 bar pressure relief valve
❑ Removing and installing ⇒ page 320
16 - Locking ring 110 Nm
❑ Ensure firm seating.
❑ Remove and install using wrench - T10202- .

3.2 Assembly overview - fuel tank (engine codes CBFA, CCTA, CCTB)

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1 - Fuel line
❑ Ensure firm seating.
2 - Cap
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4 - Tank flap unit
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❑ Removing and installing

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exterior; Rep. gr. 55 ;

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Tank flap unit; Remov‐

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ing and installing fuel

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tank flap unit .

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es, in part or in w

5 - Breather hose
t to the co

❑ Clipped onto fuel tank.

❑ Ensure firm seating.
rrectness of i

6 - Vacuum line
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❑ Clipped onto fuel tank.

❑ Ensure firm seating.
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7 - Earth connection
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❑ To protective plate for

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filler neck.
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❑ Ensure firm seating.

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9 - Clamp
10 - Fuel tank
❑ Emptying ⇒ page 277
❑ Removing and installing ⇒ page 281
❑ When removing, support using engine and gearbox jack - V.A.G 1383 A- .

276 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

11 - Securing straps
12 - Heat shield
13 - Clamping washer
14 - 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 ⇒ ETKA (Electronic parts cata‐
logue) .
15 - Sealing ring
❑ Renew
❑ When installing, fit dry in fuel tank opening.
❑ Moisten with fuel only when installing flange.
16 - Fuel delivery unit
❑ Removing and installing ⇒ page 320
❑ Checking fuel pump ⇒ page 325 .
❑ Removing and installing fuel gauge sender - G- ⇒ page 324
❑ Clean strainer if soiled

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17 - Pop rivet
18 - Protective plate
❑ For filler neck.
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20 - Flange with fuel filter ris ed
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❑ With 6.2 bar pressure aut relief valve ra
c
ss
❑ Removing and installing ⇒ page 320
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21 - Locking ring 110 Nm

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❑ Ensure firm seating.

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❑ Remove and install using wrench - T10202- .

wit
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spec
es, in part or in w

3.3 Emptying fuel tank

t to the co

Special tools and workshop equipment required

rrectness of i

♦ Fuel extraction unit - VAS 5190-

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3. Fuel tank (Passat, CC) 277

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

♦ Special wrench - T10202-

♦ Torque wrench (40 to 200 Nm) - V.A.G 1332-

– Note safety precautions before beginning work ⇒ page 272 .
Emptying fuel tank with fuel pump intact ⇒ page 278 .
Emptying fuel tank if more than 3/4 full ⇒ page 280

Emptying fuel tank if less than 3/4 full ⇒ page 280

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3.3.1 Emptying fuel tank when fuel pump is
intact
Special tools and workshop equipment required
♦ Adapter for fuel extraction - VAS 5190 /3-
♦ Test instrument adapter/DSO (5-pin) - VAS 5565-
♦ Remote control - V.A.G 1348/3A-

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WARNING
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♦ Fuel supply risedline is pressurised. Wear protective goggles
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ra
skin.ssWrap a cloth around the connection before loosening
a c
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pulling hose off connection.

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♦ Connect fuel extractor - VAS 5190- earth cable to earth.

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– Pull off supply line (metal coupling) -arrow- and catch escaping
hole

spec

fuel with a cloth.

es, in part or in w

t to the co

Note
rrectness of i

Press in securing ring to release the fuel lines.

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278 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Connect fuel extractor - VAS 5190- with adapter for fuel ex‐
tractor - VAS 5190 /3- to fuel supply line.
– Remove bench seat ⇒ General body repairs, interior; Rep. gr.
72 ; Removing and installing bench seat .
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– Remove cover -1- with fuel pump control unit - J538- -2- from

wit
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fuel delivery unit.

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es, in part or in w

t to the co
rrectness of i

cardiagn.com
l purpos

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– Pull connector -A- off fuel delivery unit flange.
or c

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

connector and fuel delivery unit.
– Connect remote control - V.A.G 1348/3A- to adapter - VAS
5565- and to battery positive (+).

Note

This step serves only to have the fuel pump running when the
engine is stopped.

– Remove filler cap from fuel tank 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

Fuel pump must not run »dry«.

3. Fuel tank (Passat, CC) 279

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017
AG. Volkswagen AG d
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3.3.2 Emptying fuelbytank ksw if it is more than e3s/ not
o
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Secure earth wire of fuel extractor - VAS 5190- to a bare metal

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part of the body.
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spec
– Use insulating tape to mark the extraction hose -arrow- at a
es, in part or in w

distance of -a- = 990 mm from the end of the hose.

t to the co
– Remove filler cap from fuel tank filler neck.
– Push extraction hose into fuel tank until marking on hose co‐

rrectness of i
incides with filler neck.
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Note

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♦ The shaft piece -1- is not used.
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♦ There is a flap on the lower end of the fuel filler neck in the fuel
or

thi
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tank which must not be damaged by the extraction hose.

t

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Therefore, only push the hose in as far as the marking.

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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.
♦ Emptying the fuel tank completely ⇒ page 280 .

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

– Remove bench seat ⇒ General body repairs, interior; Rep. gr.
72 ; Removing and installing bench seat .
– Remove cover -1- with fuel pump control unit - J538- -2- from
fuel delivery unit.

WARNING

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.

280 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Release connector -1- and fuel line -2- and pull them off flange
-3-.

Note agen
AG. Volkswagen AG d
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♦ Press in securing ring to release
rised fuel line.
b ara
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♦ On vehicles with auxiliarys heater, the connector and the fuel
au ra
c
line of the metering pump - V54- must also be disconnected.
s

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– Open locking ring using key - T10202- .

h re
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spec
urposes, in part or in wh

Caution

t to the co
Do not cant key - T10202- and press against locking ring firmly.

rrectne
If the key slips off, the fuel delivery unit can be damaged.

cardiagn.com
s
– Lift sender flange.

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f inform
– Insert extraction hose of fuel extractor - VAS 5190- as deeply
mer

as possible into fuel tank and extract fuel.

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If fuel tank needed only to be emptied, reinstall sender flange

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⇒ page 320 .
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3.4 Removing and installing fuel tank

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Special tools and workshop equipment required
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♦ Torque wrench (5 to 50 Nm) - V.A.G 1331-
co Vo
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Remove fuel tank ⇒ page 281 .

Install fuel tank ⇒ page 284 .

3.4.1 Removing fuel tank

Note

♦ The rear axle must be lowered to remove the fuel tank.

♦ Note safety precautions before beginning work ⇒ page 272 .
♦ Observe rules for cleanliness ⇒ page 274 .
♦ Assembly overview - fuel tank ⇒ page 275 .

3. Fuel tank (Passat, CC) 281

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– If necessary, empty fuel tank using fuel extractor - VAS 5190-

⇒ page 277 .
– Remove bench seat ⇒ General body repairs, interior; Rep. gr.
72 ; Removing and installing bench seat .
– Remove cover -1- with fuel pump control unit - J538- -2- from
fuel delivery unit.

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agen oes
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– Pull 5-pin connector -arrow- off flange.

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h re
hole

spec
For vehicles with auxiliary heater the metering pump - V54- con‐
es, in part or in w

nector must be separated additionally.

t to the co
– Remove rear right wheel.

rrectness of i
– Remove rear right wheel housing liner ⇒ General body re‐
l purpos

pairs, exterior; Rep. gr. 66 ; Wheel housing liner .

nform
ercia

Engine codes BZB, CAWA, CAWB, CGYA, CCZA, CCZB, CDAA,

m

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tion in
– Pull breather line and pressure retention valve -arrows- off ac‐
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Grasp securing ring (grey) on pressure retention valve and pull
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valve off upwards.
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Engine codes CBFA, CCTA, CCTB:

– Pull breather lines and vacuum line -arrows- off activated
charcoal filter.

282 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

All:
– Unclip wire from filler neck -arrows-.
– Unscrew tank flap unit securing bolt and remove tank flap unit
⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit;
Removing and installing tank flap unit .

– Unbolt filler neck from body -arrows-.

WARNING

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

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off connection.

– Separate breather line (white) -1- and fuel line (black) -2- at
connections.

Note

♦ Press in securing ring to release fuel line.

♦ Vehicles with auxiliary heater, the fuel line of the metering
pump - V54- must also be separated. n AG. Volkswagen AG do
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– Lower rear axle ⇒ Running gear, axles, steering; Rep.hogr.
ris 42 ; tee
Lowering rear axle . aut or
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♦ When lowering, ensure sufficient clearance to brake lines and

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♦ Take the help of another mechanic while unbolting and low‐

spec

ering fuel tank.

es, in part or in w

t to the co

– Hold fuel tank and unscrew bolts securing the tensioning

rrectness of i

straps -arrows-.
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– Remove tensioning straps.

– With the aid of a 2nd mechanic, lower the tank slowly and take
nform
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it out through the space between rear axle and body.

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283
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3. Fuel tank (Passat, CC)
 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

3.4.2 Installing fuel tank

– With the aid of a second mechanic, guide the filler neck in be‐
tween rear axle and body.
– Place fuel tank in mounting position and fit new securing bolts
-arrows-.

Note

To secure the securing straps for the fuel tank, only bolts with
loose washers must be used. If different bolts are used, the se‐
curing straps might twist during tightening. Bolts ⇒ ETKA (Elec‐
tronic parts catalogue) .

– Secure rear axle to body again ⇒ Running gear, axles, steer‐

ing; Rep. gr. 42 .
The remaining installation steps are carried out in the reverse or‐
der of removal. During this step, observe the following:
♦ Install breather lines and fuel lines free of kinks.

cardiagn.com
♦ Ensure that line connections are tight.
♦ Check fuel tank/body earth connection on filler neck.
– Fill fuel tank with at least 5 litres of fuel. agen
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Risk of explosion of fuel tank. If a new or completely empty fuel

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tank has been installed, it must be filled immediately with at

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least 5 litres of fuel. The fuel pump must not be allowed to run

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when the fuel tank is empty.

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Specified torques:

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urposes, in part or in wh

Component Torque setting

t to the co
Tensioning straps to body 25 Nm
♦ Use new bolts!

rrectne
♦ To secure the securing straps
for the fuel tank, only bolts with ss
loose washers must be used.
o
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This will stop the securing

inform

straps from being twisted out of

mer

position when tightening the

atio
m

bolts.
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Filler neck to body 8 Nm + 90°

t

sd
iva

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pr

Subframe/rear axle to body ⇒ Running gear, axles,

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en
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♦ Use new bolts! steering; Rep. gr. 42 ; Re‐ yi

t.
Co
moving and installing rear . Cop py
axle .
ht rig
rig ht
py by
o Vo
Fitting wheels ⇒ Running gear; Rep. gr. by c lksw
cted agen
44 ; Specified torque for Prote AG.
mounting wheels

284 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

4 Fuel tank (Golf, Scirocco)

Safety precautions when working on fuel supply system
⇒ page 272 .
Comply with rules for cleanliness ⇒ page 274 .
Assembly overview - fuel tank (engine codes BZB, CAWA,
CAWB, CGYA, CCZA, CCZB, CDAA) ⇒ page 285 .
Assembly overview - fuel tank (engine codes CBFA, CCTA,
CCTB) ⇒ page 287 .
Draining fuel tank (engine codes BZB, CAWA, CAWB, CGYA,
CCZA, CCZB, CDAA) ⇒ page 289 . . Volkswage n AG n AG d
wage oes
Emptying fuel tank (engine codes yV
oCBFA,
lks CCTA, CCTB) not
gu
⇒ page 293 . ised b ara
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Removing and installings aufuel
t
tank ⇒ page 295 . ra
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4.1 Assembly overview - fuel tank (engine codes BZB, CAWA, CAWB, CGYA,
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CCZA, CCZB, CDAA)

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1 - Securing bolt

h re
ole,

spec
2 - Cap
urposes, in part or in wh

❑ Renew if damaged

t to the co
3 - Earth connection
❑ Ensure firm seating.

rrectne
4 - 10 Nm

ss o
5 - Wiring guide
cial p

f inform
6 - 25 Nm
mer

atio

❑ Renew
om

n
c

❑ To secure the securing

i
or

n thi
e

straps for the fuel tank,

t

sd
va

only bolts with loose

i

o
pr

cum

washers must be used.

r
fo

en
ng

If different bolts are

t.
yi Co
op
used, the securing C py
t. rig
straps might twist during
gh ht
yri by
tightening. Bolts ⇒ ET‐ cop Vo
by lksw
cted
KA (Electronic parts
agen
Prote AG.
catalogue) .
7 - Fuel tank
❑ When removing, sup‐
port using engine and
gearbox jack - V.A.G
1383 A- .
❑ Removing and installing
⇒ page 295
8 - Clamping washer
9 - Exhaust system retainer
10 - Tensioning strap
❑ Observe installation po‐
sition
11 - Heat shield
12 - Supply pipe
❑ To fuel rail

4. Fuel tank (Golf, Scirocco) 285

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017
❑ Ensure firm seating.
13 - fuel filter.
❑ Fitting position ⇒ page 287
❑ Arrow points in direction of flow.
14 - Breather hose
❑ Clipped onto side of fuel tank.
❑ Ensure firm seating.
15 - Sealing ring
❑ Renew
❑ When installing, fit dry in fuel tank opening.
❑ Moisten with fuel only when installing flange.
16 - Fuel delivery unit
❑ Removing and installing ⇒ page 340
❑ Checking fuel pump ⇒ page 344 .
❑ Note installation position on fuel tank ⇒ page 286
❑ With fuel gauge sender - G-
❑ Removing and installing fuel gauge sender - G- ⇒ page 343

cardiagn.com
17 - Locking ring 110 Nm
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❑ Ensure firm seating. agen oes
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❑ Remove and install usingsewrench
d b - T10202- . ara
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18 - Supply pipe au
t or
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ss
❑ black
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❑ Clipped onto side of fuel tank.

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❑ Ensure firm seating.

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ility
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19 - Return line
wit
, is n

h re

❑ blue
hole

spec

❑ Clipped onto side of fuel tank.

es, in part or in w

t to the co

❑ Ensure firm seating.

20 - Tank flap unit
rrectness of i

❑ With rubber cup.

❑ Removing and installing ⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit; Removing and
l purpos

installing fuel tank flap unit .

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Installation position of fuel delivery unit

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• Tab -2- on flange must be between lugs -1- and -3- on fuel
or

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tank.
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• -Arrow- points in direction of travel.

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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

286 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

Location of fuel filter

Pin -2- on filter housing must engage in notch of guide -1- on filter
bracket.

4.2 Assembly overview - fuel tank (engine codes CBFA, CCTA, CCTB)

1 - Securing bolt
2 - Earth connection
AG. Volkswagen AG d
❑ Ensure firm seating. lksw
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3 - Vacuum line ise
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❑ To fuel system diagnos‐ auth
ra
tic pump - V144- ss c

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nl

pt
du

4 - 10 Nm

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itte

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5 - Rivet

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ility
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6 - Protective plate

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, is n

h re
❑ Riveted as standard to
hole

spec
bottom clamp
es, in part or in w

t to the co
❑ When replacing fuel
tank, hold protective
plate against filler pipe
and rivet to clamp

rrectness of i
7 - Cable bracket
l purpos

❑ Clipped onto protective

plate nf
ercia

orm

8 - 25 Nm
m

atio
m

❑ Renew
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❑ To secure the securing

thi
te

sd
a

straps for the fuel tank,

iv

o
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rp

cu

only bolts with loose

o

m
f

washers must be used.

en
ng

t.
yi
If different bolts are
Co
Cop py
used, the securing
t. rig
gh ht
yri
straps might twist during
p by
co Vo
by lksw
tightening. Bolts ⇒ ET‐ Prote
cted AG.
agen
KA (Electronic parts
catalogue) .
9 - Fuel tank
❑ When removing, sup‐
port using engine and
gearbox jack - V.A.G 1383 A- .
❑ Removing and installing ⇒ page 295
10 - Clamping washer
11 - Exhaust system retainer
12 - Tensioning strap
❑ Observe installation position

4. Fuel tank (Golf, Scirocco) 287

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

13 - Heat shield
14 - Supply pipe
❑ To fuel rail
❑ Ensure firm seating.
15 - fuel filter.
❑ Fitting position ⇒ page 289
❑ Arrow points in direction of flow.
16 - Vacuum line
❑ From fuel system diagnostic pump - V144- to intake manifold.
❑ Clipped onto fuel tank.
❑ Ensure firm seating.
17 - Breather hose
❑ From activated charcoal filter to activated charcoal filter solenoid valve 1 - N80-
❑ Clipped onto side of fuel tank.
❑ Ensure firm seating.
18 - Sealing ring

cardiagn.com
❑ Renew
❑ When installing, fit dry in fuel tank opening.
❑ Moisten with fuel only whenAinstalling flange.
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19 - Fuel delivery unit y Volks not
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❑ Removing and orise installing ⇒ page 340 nte
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❑ If fuel delivery
ss au
unit was renewed, adapt engine control unitr ato fuel pump ⇒ Vehicle diagnostic tester
c
“Guided Functions”.
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❑ Checking fuel pump ⇒ page 344 .

an
d
itte

y li

❑ Note installation position on fuel tank ⇒ page 289

rm

ab
pe

ility

❑ With fuel gauge sender - G-

ot

wit
, is n

❑ Removing and installing fuel gauge sender - G- ⇒ page 343

h re
hole

spec

❑ Clean strainer if soiled

es, in part or in w

t to the co

20 - Locking ring 110 Nm

❑ Ensure firm seating.
❑ Remove and install using wrench - T10202- .
rrectness of i

21 - Return line
l purpos

❑ blue
❑ Clipped onto side of fuel tank.
nform
ercia

❑ Ensure firm seating.

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com

tio

22 - Cap
n in
r
te o

thi

❑ Renew if damaged
s
iva

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rp

23 - Tank flap unit

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❑ With rubber cup.

n

t.
yi Co
op py
❑ Removing and installing ⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit; Removing and
t. C rig
gh ht
yri
installing fuel tank flap unit . p by
co Vo
by lksw
cted agen
24 - To activated charcoal filter Prote AG.

25 - Supply pipe
❑ black
❑ Clipped onto side of fuel tank.
❑ Ensure firm seating.

288 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

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.

Location of fuel filter

Pin -2- on filter housing must engage in notch of guide -1- on filter
bracket.

AG. Volkswagen AG d
agen

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4.3 Draining fuel tank (engine codes BZB,
itte

y li
erm

ab
CAWA, CAWB, CGYA, CCZA, CCZB,

ility
ot p

wit
CDAA)
, is n

h re
hole

spec
Special tools and workshop equipment required
es, in part or in w

♦ Fuel extraction unit - VAS 5190- t to the co

rrectness of i
l purpos

nf
ercia

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m

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om

n in
or c

thi
te

sd
iva

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rp

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o

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f

en
ng

t.
yi Co
♦ Special wrench - T10202- t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Torque wrench (40 to 200 Nm) - V.A.G 1332-

4. Fuel tank (Golf, Scirocco) 289

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Note safety precautions before beginning work ⇒ page 272 .

Emptying fuel tank with fuel pump intact ⇒ page 290 .
Emptying fuel tank if more than 3/4 full ⇒ page 291

Emptying fuel tank if less than 3/4 full ⇒ page 292

4.3.1 Emptying fuel tank when fuel pump is

intact
Special tools and workshop equipment required
♦ Adapter for fuel extraction - VAS 5190 /3- AG. Volkswagen AG d
agen oes
ksw
♦ Test instrument adapter/DSO (5-pin) by - VAS 5565-
Vol not
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♦ Remote control - V.A.G 1348/3A-
hor eo
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ce
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WARNING
un

pt
an
d
itte

y li
♦ Fuel supply line is pressurised. Wear protective goggles
rm

ab
pe

ility
and protective clothing to avoid injury and contact with the
ot

wit
skin. Wrap a cloth around the connection before loosening
, is n

cardiagn.com
h re
hose connections. Then release pressure by carefully
hole

pulling hose off connection.

spec
es, in part or in w

t to the co
♦ Connect fuel extractor - VAS 5190- earth wire to vehicle
earth.

rrectness of i
– Pull off supply line (metal coupling) -arrow- and catch escaping
l purpos

fuel with a cloth.

nform
ercia

Note
m

a
com

tion in

Press in securing ring to release the fuel lines.

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te o

thi
s
iva

do
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rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
– Connect fuel extractor - VAS 5190- with adapter for fuel ex‐
Prote AG.

tractor - VAS 5190 /3- to fuel supply line.

– Remove bench seat ⇒ General body repairs, interior; Rep. gr.
72 ; Removing and installing bench seat .

290 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Remove cover -1- with fuel pump control unit - J538- -2- from
fuel delivery unit.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
d
– Unplug connector -arrow-. horise nte
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itte

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ility
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wit
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cardiagn.com
hole

spec
es, in part or in w

t to the co
rrectness of i
– Connect test instrument adapter/DSO (5-pin) - VAS 5565- to
l purpos

connector and fuel delivery unit.

– Connect remote control - V.A.G 1348/3A- to test instrument

nf
ercia

adapter/DSO (5-pin) - VAS 5565- and to battery positive (+).

orm
m

atio
om

n in
c

Note
or

thi
te

sd
iva

This step serves only to have the fuel pump running when the
o
r
rp

cu

engine is stopped.
o

m
f

en
ng

t.
yi Co
Cop py
– Remove filler cap from fuel tank filler neck. ht. rig
rig ht
py by
o Vo
– Operate remote control - V.A.G 1348/3A- and shut-off tap on by c lksw
cted agen
fuel extractor - VAS 5190- until fuel tank is empty.
Prote AG.

Caution

Fuel pump must not run »dry«.

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

full

Caution

Secure earth wire of fuel extractor - VAS 5190- to a bare metal

part of the body.

4. Fuel tank (Golf, Scirocco) 291

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Remove cotter -2- from shaft -1- of fuel extractor - VAS 5190- .
– At a distance of -a- = 1180 mm from the end of the hose, mark
extraction hose with insulating tape -arrow-.

– Remove filler cap from fuel tank filler neck.

– Screw shaft end -1- of fuel extractor unit - VAS 5190- onto fuel
filler neck.
– Push extraction hose into fuel tank until marking on hose
-arrow- coincides with shaft end.
n AG. Volkswagen AG do
lkswage es n
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byV ua
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Note

wit
is n

h re
ole,

A ball valve -2- is located at the bottom of the filler neck in the fuel

spec
tank -1-; it must not be damaged by the extraction hose -3-.
urposes, in part or in wh

Therefore push hose into filler neck only as far as marking

t to the co
-arrow-.
rrectne
– Drain fuel tank as much as possible through fuel filler neck.
– Carefully pull out extraction hose.
ss o
cial p

f inform

Note
mer

atio
om

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

n
c

i
or

enough for the sender flange to be opened without danger.

thi
te

sd

The tank may be removed while containing remaining fuel.

iva

o
pr

cum
r

♦ Emptying the fuel tank completely ⇒ page 292 .

fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
4.3.3 Emptying fuel tank if it is less than 3/4 full pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove bench seat ⇒ General body repairs, interior; Rep. gr.
72 ; Removing and installing bench seat .

292 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Remove cover -1- with fuel pump control unit - J538- -2- from
fuel delivery unit.

WARNING

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.

– Unplug connector -arrow-.

cardiagn.com
– Pull fuel lines -1- and -2- off the flange.

Note
AG. Volkswagen AG d
agen oes
lksw not
♦ Press in securing ring tod brelease
yV
o the fuel lines. gu
ara
ise n
♦ On vehicles with auxiliary
ut
hor
heater, the connector and the fuel tee or
line of the metering
ss pump - V54- must also be disconnected.
a ac
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re

– Open locking ring using key - T10202- and raise flange slightly.
hole

spec
es, in part or in w

t to the co

Caution

Do not cant key - T10202- and press against locking ring firmly.
rrectness of i

If the key slips off, the fuel delivery unit can be damaged.
l purpos

– Insert extraction hose of fuel extractor - VAS 5190- as deeply

nform
ercia

as possible into fuel tank and extract fuel.

m

If fuel tank needed only to be emptied, reinstall sender flange

at
om

io

⇒ page 340 .
n
c

in t
or

his
ate

4.4 Emptying fuel tank (engine codes

do
priv

cum
or

CBFA, CCTA, CCTB)

f

en
ng

t.
yi Co
op py
Special tools and workshop equipment required
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

4. Fuel tank (Golf, Scirocco) 293

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

♦ Special wrench - T10202-

♦ Fuel extraction unit - VAS 5190-

cardiagn.com
♦ Torque wrench - V.A.G 1332-
– Note safety precautions before beginning work ⇒ page 272 .
AG. Volkswagen AG d
agen oes
Caution olksw not
byV gu
ara
ed
ris nte
Secure earth wire of fuel extractor - VAS
ut
ho 5190- to a bare metal eo
ra
part of the body. ss a c
ce
e
nl

pt
du

an
itte

y li

– Remove cotter -2- from shaft -1- of fuel extractor - VAS 5190- .
erm

ab
ility
ot p

– At a distance of -a- = 1500 mm from the end of the hose, mark

wit

extraction hose with insulating tape -arrow-.

, is n

h re
hole

– Remove filler cap from fuel tank filler neck.

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

294 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Screw shaft end -1- of fuel extractor unit - VAS 5190- onto fuel
filler neck.

Note

On vehicles with plug-in connector, the shaft section of the fuel

extractor must be held accordingly.
. Volkswag AG en AG
agen does
olksw not
– Insert suctioned b hose in fuel tank until marking -arrow-
y V gu
ara (previ‐
ously made)
horis is at the shaft section and extract fuel
nte⇒ Oper‐
e
atingauinstructions
t
for fuel extractor - VAS 5190- . or
ac
ss

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le
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pt
an
d

Note
itte

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erm

ab
ility
♦ After approx. 120 cm a pressure point is noticeable. The non-
ot p

wit
return flap in the fuel tank must be pushed open. Pull the hose
is n

h re
out slightly and push it in with a slight jerk.
ole,

spec
urposes, in part or in wh

♦ The fuel tank is emptied almost completely in this way.

t to the co
♦ Proceed in same manner when pulling hose out.

cardiagn.com
rrectne
4.5 Removing and installing fuel tank
ss
Special tools and workshop equipment required o
cial p

f inform
♦ Torque wrench (5 to 50 Nm) - V.A.G 1331-
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

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

Removing fuel tank

– Note safety precautions before beginning work ⇒ page 272 .
– Observe rules for cleanliness ⇒ page 274 .
– If necessary, empty fuel tank using fuel extractor - VAS 5190- :
Engine codes BZB, CAWA, CAWB, CGYA, CCZA, CCZB,
CDAA ⇒ page 289 .

4. Fuel tank (Golf, Scirocco) 295

 AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
CC 2010 ➤ , Eos ut
h 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat
o e o 2006 ➤ , ...
ra
a
4-cyl. injection
s engine (1.8 and 2.0 l engine, chain drive) - Edition
s c 02.2017

ce
le
un

pt
Engine codes CBFA, CCTA, CCTB ⇒ page 293 .

an
d
itte

y li
rm

ab
– Remove bench seat ⇒ General body repairs, interior; Rep. gr.
pe

ility
72 ; Removing and installing bench seat .
ot

wit
, is n

h re
– Remove cover -1- with fuel pump control unit - J538- -2- from
hole

spec
fuel delivery unit.
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
– Unplug connector -arrow-.

s
iva

do
r
rp

cum
fo

en
ng

t.
yi
Note
Co
Cop py

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ht. rig
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For vehicles with auxiliary heater the metering pump - V54- con‐ copy Vo
by lksw
nector must be separated additionally. cted agen
Prote AG.

– Remove rear right wheel.

– Remove rear right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liner .
– Unscrew tank flap unit securing bolt and remove tank flap unit
⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit .

Engine codes CAWB, CCZA, CCZB, CDAA:

– Unbolt filler neck from body -1-.
– Unclip electrical wiring -2- from filler neck.

296 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

Engine codes CBFA, CCTA:

– Disconnect hoses -1- and -2-.
– Unbolt filler neck from body -arrows-.
– Unclip electrical wiring from filler neck.
AG. Volkswagen AG d
All: ksw
agen oes
not
Vol
y gu
– Remove centre and ise
d rear silencers.
b ara
nte
or eo
h
– Remove heat
s a shields from middle and rear silencers.
ut ra
c
s

ce
le
un

pt
WARNING

an
d
itte

y li
rm

ab
pe

Fuel supply line is pressurised. Wear protective goggles and

ility
ot

protective clothing to avoid injury and contact with the skin.

wit
, is n

Wrap a cloth around the connection before loosening hose

h re
hole

connections. Then release pressure by carefully pulling hose

spec
off connection.
es, in part or in w

t to the co
rrectness of i

cardiagn.com
Note
l purpos

Press in securing ring to release the fuel lines.

nform
mercia

– Disconnect breather line -1- (white) and fuel line -2- (black) at

a
com

tio
connecting point.
n in
r
te o

thi
s
iva

do
r

Note
rp

cum
fo

en
ng

t.
yi
♦ On vehicles for USA/Canada, the vacuum line for the fuel sys‐
Co
Cop py
tem diagnostic pump - V144- must be separated in addition.
t. rig
gh ht
pyri by
Vo
o
♦ Vehicles with auxiliary heater, the fuel line of the metering
c by lksw
cted agen
pump - V54- must also be separated.
Prote AG.

4. Fuel tank (Golf, Scirocco) 297

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Unscrew securing strap and securing bolts. When doing this,

support fuel tank with engine and gearbox jack - V.A.G 1383
A- .
– Lower fuel tank.
Installing fuel tank:
Install in reverse order of removal. During this step, observe the
following:
Specified torques: Assembly overview - fuel tank.
Engine codes BZB, CAWA, CAWB, CGYA, CCZA, CCZB,
CDAA ⇒ page 285 .
Engine codes CBFA, CCTA,geCCTB
n AG. Vo⇒
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wagen287
AG d .
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♦ To secure the securing by straps for the fuel tank, only bolts
V t gu with
ara
ed
loose washers mustris be used. If different bolts are used, thente
ho eo
securing straps
aut might twist during tightening. ra
ss c
♦ Install breather lines and fuel lines free of kinks.

ce
le
un

pt
an
d

♦ Do not interchange supply line and return line (return line blue
itte

y li
erm

or with blue marking, supply line black).

ab
ility
ot p

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♦ Ensure wiring/line connections are secured properly by pulling

wit
is n

back.

h re
ole,

spec
♦ Check earth connection on fuel tank and body to filler neck.
urposes, in part or in wh

t to the co
– Fill fuel tank with at least 5 litres of fuel.
rrectne

WARNING

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

ss o

tank has been installed, it must be filled immediately with at

cial p

f i

least 5 litres of fuel. The fuel pump must not be allowed to run
nform

when the fuel tank is empty.

mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

298 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

5 Fuel tank (Tiguan)

Assembly overview - fuel tank ⇒ page 299 .
Drain fuel tank ⇒ page 301 .
Removing and installing fuel tank ⇒ page 304 .

5.1 Assembly overview - fuel tank

1 - Cap
❑ Renew if damaged
2 - Securing bolt n AG. Volkswagen AG do
lkswage es n
o ot g
3 - Earth connection d byV ua
ran
ir se
❑ Ensure firm seating. tho tee
or
au ac
4 - Breather hose ss

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nl

❑ To activated charcoal fil‐

pt
du

an
itte

ter

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erm

ab
❑ Ensure firm seating.

ility

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wit
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5 - Locking ring 110 Nm

h re
hole

❑ Ensure firm seating.

spec
es, in part or in w

❑ Remove and install us‐

t to the co
ing fuel tank sender unit
tool - 3087- .

rrectness of i
6 - Fuel delivery unit
❑ Removing and installing
l purpos

⇒ page 360
❑ Checking fuel pump

nform
ercia

⇒ page 368 .
m

❑ Note installation posi‐

at
om

io
tion on fuel tank

n
c

in t
r

⇒ page 300
o

his
ate

❑ With fuel gauge sender

do
priv

c
- G-

um
for

en
ng

❑ Removing and installing

t.
yi Co
op
fuel gauge sender - G-
C py
t. rig
gh
⇒ page 363
ht
pyri by
Vo
co lksw
❑ Clean strainer if soiled
by
cted agen
Prote AG.
7 - Supply pipe
❑ black
❑ Clipped onto side of fuel
tank.
❑ Ensure firm seating.
8 - Flange on left side
❑ With fuel gauge sender 2 - G169- .
❑ With suction-jet pump
❑ With pressure limiting valve
❑ With fuel filter
❑ Removing and installing ⇒ page 366

5. Fuel tank (Tiguan) 299

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

9 - 3.5 Nm
10 - Bracket for fuel pump control unit - J538-
11 - Fuel pump control unit - J538-
❑ Removing and installing ⇒ page 367
12 - Sealing ring
❑ Renew if damaged
❑ When installing, fit dry in fuel tank opening.
❑ Moisten with fuel only when installing flange.
13 - Fuel tank
❑ When removing, support using engine and gearbox jack - V.A.G 1383 A- .
❑ Removing and installing ⇒ page 304
14 - 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 ⇒ ETKA (Electronic parts cata‐
logue) .
15 - Tensioning strap

cardiagn.com
❑ Observe installation position
16 - 25 Nm wage
n AG. Volkswagen AG do
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❑ Renew d byV ua
ran
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17 - Clamping washerutho
or
a ac
ss
18 - Heat shield
ce
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un

pt
an

19 - Breather hose
d
itte

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erm

ab

❑ Clipped onto side of fuel tank.

ility
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❑ Ensure firm seating.

wit
is n

h re

20 - Breather hose
ole,

spec
urposes, in part or in wh

❑ Ensure firm seating.

t to the co

21 - 8 Nm + 1/4 turn further (90°)

❑ Renew
rrectne

22 - Tank flap unit

s

❑ With rubber cup.

s o
cial p

❑ Removing and installing ⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit; Removing and
inform

installing fuel tank flap unit .

mer

atio
om

n
c

i
or

Installation position of flange for fuel delivery unit and fuel gauge
thi
te

sd
a

sender 2 - G169-
iv

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pr

cum
r
fo

Fuel delivery unit -3-:

en
ng

t.
yi Co
op
The lug -1- points in direction of travel. C py
t. rig
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yri by
Fuel gauge sender 2 - G169- -2-: cop Vo
by lksw
cted agen
Prote
The lug -1- points in direction of travel.
AG.

Note

The arrows on the locking rings may be disregarded.

300 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

5.2 Emptying fuel tank

Special tools and workshop equipment required
♦ Fuel extraction unit - VAS 5190-

♦ Fuel tank sender unit tool - 3087-

n AG. Volkswagen AG do
swage es n

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d ran
ir se tee
tho
u or
a ac
ss

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nl

pt
du

an
itte

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ility
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wit
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h re
hole

spec
♦ Torque wrench (40 to 200 Nm) - V.A.G 1332-
es, in part or in w

t to the co
– Note safety precautions before beginning work ⇒ page 272 .
Emptying fuel tank with fuel pump intact ⇒ page 301 .

rrectness of i
Emptying fuel tank if more than 3/4 full ⇒ page 303
l purpos

Emptying fuel tank if less than 3/4 full ⇒ page 303

nf
ercia

5.2.1 Emptying fuel tank when fuel pump is

orm
m

atio

intact
om

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thi

Special tools and workshop equipment required

te

sd
iva

o
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♦ Adapter for fuel extraction - VAS 5190 /3-

rp

cu
o

m
f

en
ng

♦ Test instrument adapter/DSO (5-pin) - VAS 5565-

t.
yi Co
Cop py
. rig
♦ Remote control - V.A.G 1348/3A-
t
gh ht
pyri by
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co lksw
by
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Prote
WARNING
AG.

♦ 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 - VAS 5190- earth wire to vehicle
earth.

5. Fuel tank (Tiguan) 301

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Pull off supply line (metal coupling) -arrow- and catch escaping
fuel with a cloth.

Note

Press in securing ring to release the fuel lines.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
– Connect fuel extractor - VAS 5190- with adapter for fuel ex‐

ce
e
nl

pt
tractor - VAS 5190 /3- to fuel supply line.
du

an
itte

y li
– Remove bench seat ⇒ General body repairs, interior; Rep. gr.
erm

ab
ility
72 ; Removing and installing bench seat .
ot p

wit
, is n

– Remove cover from fuel delivery unit.

h re
hole

spec
es, in part or in w

t to the co

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– Pull 5-pin connector -1- off right flange (in direction of travel).

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– 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.

– Remove filler cap from fuel tank 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

Fuel pump must not run »dry«.

302 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

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

full

Caution

Secure earth wire of fuel extractor - VAS 5190- to a bare metal

part of the body.
AG. Volkswagen AG d
agen oes
olksw not
– Use insulating tape to mark the extraction
ed by
V
hose -arrow- at a gu
ara
distance of -a- = 1200 mm from the horis end of the hose. nte
eo
aut ra
– Remove filler cap from fuel tank
s filler neck.
s c

ce
le
un

pt
– Push extraction hose into fuel tank until marking on hose co‐

an
d
itte

incides with filler neck.

y li
erm

ab
ility
ot p

wit
is n

Note

h re
ole,

spec
urposes, in part or in wh

♦ The shaft piece -1- is not used.

t to the co

cardiagn.com
♦ There is a flap on the lower end of the fuel filler neck in the fuel
tank which must not be damaged by the extraction hose.
Therefore, only push the hose in as far as the marking.

rrectne
– Drain fuel tank as much as possible through fuel filler neck.

ss o
– Carefully pull out extraction hose.
cial p

f inform
mer

atio
m

Note
o

n
c

i
or

n thi
e

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

t

sd
va

enough for the sender flange to be opened without danger.

i

o
pr

cum
r

The tank may be removed while containing remaining fuel.

fo

en
ng

t.
yi Co
♦ Emptying the fuel tank completely ⇒ page 303 . Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
5.2.3 Emptying fuel tank if it is less than 3/4 full
agen
Prote AG.

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

72 ; Removing and installing bench seat .
– Remove cover from fuel delivery unit.

WARNING

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.

– Pull connector and fuel lines off flange.

Note

Press buttons on hose couplings to do this.

5. Fuel tank (Tiguan) 303

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Open locking ring using fuel tank sender wrench - 3087- .

– Raise fuel delivery unit.
– Insert extraction hose of fuel extractor - VAS 5190- as deeply
as possible into fuel tank and extract fuel.
If fuel tank needed only to be emptied, install fuel delivery unit
again ⇒ page 360 .

5.3 Removing and installing fuel tank

Special tools and workshop equipment required
♦ Torque wrench (5 to 50 Nm) - V.A.G 1331-

cardiagn.com
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

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

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

Removing
thi
te

sd
iva

– Note safety precautions before beginning work ⇒ page 272 .

o
pr

cum
r
fo

en
ng

– First check whether a coded radio is fitted. If so, obtain anti-

t.
yi Co
theft code. Cop py
ht. rig
rig ht
– With the ignition switched off, disconnect battery earth strap. py by
co Vo
by lksw
cted agen
– Unscrew securing bolts and remove tank flap unit.
Prote AG.

– Drain fuel tank and clean fuel filler neck and surrounding area.
– Remove bench seat ⇒ General body repairs, interior; Rep. gr.
72 ; Removing and installing bench seat .
– Remove cover from fuel delivery unit.

304 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Pull connector -1- and fuel line -2- off right flange (in direction
of travel).

– Release connector -arrow- on fuel pump control unit - J538-

using assembly tool - T10118- and pull it off.

cardiagn.com
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
ut ra
– Pull connector -1- off left
ss a flange (in direction of travel). c

ce
e

– Remove rear exhaust system with centre and rear silencers.

nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– First, undo bolt -1- and then bolts -2…3- and remove pendu‐
lum support.
nform
ercia

– Remove propshaft ⇒ Propshaft and rear final drive; Rep. gr.

m

39 ; Removing and installing propshaft .

at
om

ion
c

in t
or

his

WARNING
ate

do
priv

cum
or

Fuel supply lines are under pressure! Wear eye protection and
f

en
ng

gloves to avoid injuries and skin contact. Wrap a cloth around

t.
yi Co
op
the connection before loosening hose connections. Then re‐
C py
ht. rig
lease pressure by carefully pulling hose off connection. rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

5. Fuel tank (Tiguan) 305

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Disconnect fuel line -1- (black) and breather line -2- (white) at
connecting point.
– If an auxiliary heater is fitted, also separate fuel line -3-.

Note
olkswagen AG
en AG. V
Press in securing ring to release the fuel lines. olkswag does
not
yV gu
db ara
ise nte
– Remove rear right wheel. tho
r eo
s au ra
c
– Remove rear right wheel housing s liner ⇒ General body re‐

ce
e

pairs, exterior; Rep. gr. 66 ; Wheel housing liner .

nl

pt
du

an
itte

y li
erm

ab
Engine codes BZB, CAWA, CAWB, CGYA:

ility
ot p

wit
– Disconnect breather lines -1- from activated charcoal filter and
, is n

h re
fuel filler neck -3-.
hole

spec
– Unclip wheel sensor wire -2- from retainer on filler neck.
es, in part or in w

t to the co

cardiagn.com
rrectness of i
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nform
mercia

at
Engine codes CBFA, CCTA, CCTB:
om

ion
c

in t
r

– Pull breather lines and vacuum line -arrows- off activated

o

his
te

charcoal filter.
a

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Unclip wheel sensor wire -arrows- from retainer on filler neck.

All:
– Remove tank flap and fuel tank filler neck cap.
– Disconnect earth cable at fuel filler neck.

306 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Unbolt filler neck from body -arrows-.

– Remove securing bolt -1-.

AG. Volkswagen A
– Unscrew securing ksstrap
wage and securing bolts
n G do
es-arrows-.
not When
doing this, supportVol fuel tank with engine and gearbox
ara jack -
by gu
d
V.A.G 1383
or A- .
ise nte
e
h
ut or
Installingss a ac

ce
le

– With the aid of a second mechanic, guide the filler neck in be‐
un

pt
an
d

tween rear axle and body. Then place fuel tank on engine and
itte

y li

cardiagn.com
erm

gearbox jack - V.A.G 1383 A- .

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
– Raise fuel tank slowly up to installation position and secure it
in place.
rrectne

Note
ss o

To secure the securing straps for the fuel tank, only bolts with
cial p

f in

loose washers must be used. If different bolts are used, the se‐
form
mer

curing straps might twist during tightening.

atio
om

n
c

– Tighten the new bolts of the securing straps -arrows- and the
or

n thi
e

new bolt -1- to 25 Nm.

t

sd
iva

o
pr

cum
r
fo

en
ng

t.
– Tighten securing bolts -arrows- for fuel filler neck to 8 Nm +
yi Co
op py
additional 1/4 (90°) turn. t. C rig
gh ht
pyri by
Vo
o
Further installation is carried out in reverse order of removal. Dur‐
by c lksw
cted agen
ing this step, observe the following:
Prote AG.

♦ Install breather lines and fuel lines free of kinks.

♦ Check earth connection on fuel tank and body to filler neck.
♦ Ensure that line connections are tight.
♦ After installing fuel tank, check that supply and breather lines
are still clipped onto fuel tank.
– Fill fuel tank with at least 5 litres of fuel.

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.

5. Fuel tank (Tiguan) 307

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

6 Fuel tank (Eos)

Safety precautions when working on fuel supply system
⇒ page 272 .
Comply with rules for cleanliness ⇒ page 274 .
Assembly overview - fuel tank (engine codes CBFA, CCTA,
CCTB) ⇒ page 310 .
Assembly overview - fuel tank (engine codes CAWA, CAWB,
CCZA, CCZB) ⇒ page 308 .
Drain fuel tank ⇒ page 312 .
Removing and installing fuel tank ⇒ page 316 .
olkswagen AG
en AG. V
6.1 Assembly overview
yV
olk-s fuel tank (engine codes
wag does
not
g
CAWA, CAWB, CCZA, CCZB)
b ua
ed ran
oris tee
th or
1 - Securing bolt au ac
ss

ce
le

2 - Cap
un

pt
an
d

❑ Renew if damaged
itte

y li

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erm

ab
3 - Earth connection

ility
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wit
❑ Ensure firm seating.
is n

h re
ole,

4 - 10 Nm

spec
urposes, in part or in wh

5 - Cable bracket

t to the co
6 - 25 Nm
❑ Renew
rrectne
❑ To secure the securing
straps for the fuel tank,
ss o

only bolts with loose

cial p

f i

washers must be used.

nform

If different bolts are

mer

atio

used, the securing

om

straps might twist during

n
c

i
or

tightening.
thi
te

sd
va

7 - Fuel tank
i

o
pr

cum
r
fo

❑ When removing, sup‐

en
ng

t.
yi
port using engine and
Co
Cop py
gearbox jack - V.A.G
t. rig
gh ht
yri
1383 A- . p by
o Vo
by c lksw
cted
❑ Removing and installing
agen
Prote AG.
⇒ page 316
8 - Clamping washer
9 - Exhaust system retainer
10 - Tensioning strap
❑ Observe installation po‐
sition
❑ 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.
11 - Heat shield
12 - Supply pipe
❑ To fuel rail
❑ Ensure firm seating.

308 Rep. gr.20 - Fuel supply system

 AG. Volkswagen AG d
agen oes
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13 - fuel filter.

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❑ Fitting position ⇒ page 310

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❑ Arrow points in direction of flow.

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14 - Breather hose

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❑ Clipped onto side of fuel tank.

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❑ Ensure firm seating.
15 - Sealing ring

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❑ When installing, fit dry in fuel tank opening.

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❑ Moisten with fuel only when installing flange.
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16 - Fuel delivery unit
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❑ Removing and installing ⇒ page 340
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❑ Checking fuel pump ⇒ page 344 .
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❑ Note installation position on fuel tank ⇒ page 309

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❑ With fuel gauge sender - G-
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❑ Removing and installing fuel gauge sender - G- ⇒ page 343
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17 - Locking ring 110 Nm
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❑ Ensure firm seating.
❑ Remove and install using wrench - T10202- .
18 - Supply pipe
❑ black
❑ Clipped onto side of fuel tank.
❑ Ensure firm seating.
19 - Return line
❑ blue
❑ Clipped onto side of fuel tank.
❑ Ensure firm seating.
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.

6. Fuel tank (Eos) 309

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

Location of fuel filter

Pin -2- on filter housing must engage in notch of guide -1- on filter
bracket.

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6.2 Assembly overview - fuel tank (engine codes CBFA, CCTA, CCTB)
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1 - Securing bolt

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2 - Earth connection

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❑ Ensure firm seating.

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3 - 11 Nm

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4 - Rivet
5 - Protective plate
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❑ Riveted as standard to
bottom clamp

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plate against filler pipe
or c

and rivet to clamp

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6 - Cable bracket
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❑ 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.
8 - Fuel tank
❑ When removing, sup‐
port using engine and
gearbox jack - V.A.G
1383 A- .
❑ Removing and installing
⇒ page 317
9 - Clamping washer
10 - Exhaust system retainer
11 - Tensioning strap
❑ Observe installation position
12 - Heat shield
13 - Supply pipe
❑ To fuel rail

310 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

14 - fuel filter.
❑ Fitting position ⇒ page 312
❑ Arrow points in direction of flow.
15 - Vacuum line
❑ green
❑ From fuel system diagnostic pump - V144- to intake manifold.
❑ Clipped onto fuel tank.
❑ Ensure firm seating.
16 - Breather hose
❑ white
❑ From activated charcoal filter to activated charcoal filter solenoid valve 1 - N80-
❑ Clipped onto side of fuel tank.
❑ Ensure firm seating.
17 - Sealing ring
❑ Renew
❑ When installing, fit dry in fuel tank opening.
❑ Only when installing, moisten inside of flange with fuel

cardiagn.com
18 - Fuel delivery unit
❑ Removing and installing ⇒ page 340
❑ Checking fuel pump ⇒ page 344 .
❑ Note installation position on fuel tank ⇒ page 312
❑ With fuel gauge sender - G-
❑ Removing and installing fuel gauge sender - G- ⇒ page 343
❑ Clean strainer if soiled
19 - Locking ring 110 Nm
❑ Ensure firm seating.
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❑ Ensure firm seating.

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22 - Tank flap unit

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❑ With rubber cup.

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❑ Removing and installing ⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit; Removing and
installing fuel tank flap unit .
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23 - Supply pipe
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❑ black
❑ Clipped onto side of fuel tank.
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❑ Ensure firm seating.

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6. Fuel tank (Eos) 311

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

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.

Location of fuel filter

Pin -2- on filter housing must engage in notch of guide -1- on filter
bracket.

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♦ Fuel extraction unit - VAS 5190-

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♦ Torque wrench (40 to 200 Nm) - V.A.G 1332-

– Note safety precautions before beginning work ⇒ page 272 .

312 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

Emptying fuel tank with fuel pump intact ⇒ page 313 .

Emptying fuel tank if more than 3/4 full ⇒ page 314

Emptying fuel tank if less than 3/4 full ⇒ page 315

6.3.1 Emptying fuel tank when fuel pump is

intact
Special tools and workshop equipment required
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♦ Adapter for fuel extraction - VAS
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♦ Remote control - sV.A.G
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♦ Fuel supply line is pressurised. Wear protective goggles

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and protective clothing to avoid injury and contact with the

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skin. Wrap a cloth around the connection before loosening

h re
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hose connections. Then release pressure by carefully

spec
pulling hose off connection.

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♦ Connect fuel extractor - VAS 5190- earth wire to vehicle
earth.

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– Pull off supply line (metal coupling) -arrow- and catch escaping
fuel with a cloth.

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Press in securing ring to release the fuel lines.

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– Connect fuel extractor - VAS 5190- with adapter for fuel ex‐
tractor - VAS 5190 /3- to fuel supply line.
– Remove bench seat ⇒ General body repairs, interior; Rep. gr.
72 ; Removing and installing bench seat .

6. Fuel tank (Eos) 313

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Remove cover -1- with fuel pump control unit - J538- -2- from
fuel delivery unit.

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– Unplug connector -arrow-.

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

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connector and fuel delivery unit.

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– Connect remote control - V.A.G 1348/3A- to test instrument
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Note

This step serves only to have the fuel pump running when the
engine is stopped.

– Remove filler cap from fuel tank 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

Fuel pump must not run »dry«.

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

full

Caution

Secure earth wire of fuel extractor - VAS 5190- to a bare metal

part of the body.

314 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Remove cotter -2- from shaft -1- of fuel extractor - VAS 5190- .
– At a distance of -a- = 820mm from the end of the hose, mark
extraction hose with insulating tape -arrow-.

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– Push extraction hose into fuel tank until marking -arrow- on

ab
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hose coincides with filler neck.
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Note
es, in part or in w

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A ball valve is located at the lower end of filler neck in fuel tank,
which must not be damaged by the extraction hose -1-. Therefore
push hose into filler neck only as far as marking -arrow-.

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– Empty fuel tank as far as possible.

– Carefully pull out extraction hose.

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

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enough for the sender flange to be opened without danger.

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♦ If the fuel tank has to be drained fully, proceed as follows:

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⇒ page 315 . C py
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6.3.3 Emptying fuel tank if it is less than 3/4 full
Prote AG.

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

72 ; Removing and installing bench seat .
– Remove cover -1- with fuel pump control unit - J538- -2- from
fuel delivery unit.

WARNING

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.

6. Fuel tank (Eos) 315

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Unplug connector -arrow-.

– Pull fuel lines -1- and -2- off the flange.

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♦ Press in securing ed byring to release the fuel lines. gu
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♦ On vehicles aut with auxiliary heater, the connector and the fuel
h
ra
line of the
s metering pump - V54- must also be disconnected.c
s

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– Open locking ring using key - T10202- and raise flange slightly.
hole

spec
es, in part or in w

t to the co

Caution

Do not cant key - T10202- and press against locking ring firmly.
rrectness of i

If the key slips off, the fuel delivery unit can be damaged.
l purpos

– Insert extraction hose of fuel extractor - VAS 5190- as deeply

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as possible into fuel tank and extract fuel.

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If fuel tank needed only to be emptied, reinstall sender flange

ion
c

⇒ page 340 .
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6.4 Removing and installing fuel tank

p

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Special tools and workshop equipment required
Co
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♦ Torque wrench (5 to 50 Nm) - V.A.G 1331-
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

316 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

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

Remove fuel tank ⇒ page 317 .

Install fuel tank ⇒ page 319 .

6.4.1 Removing
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– If necessary, empty fuel tank using fuel extractor - VAS ris5190-
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⇒ page 312 . au
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– Remove bench seat ⇒ General body repairs, interior; Rep. gr.

ce
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pt
72 ; Removing and installing bench seat .

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– Remove cover -1- with fuel pump control unit - J538- -2- from

ab
pe

ility
fuel delivery unit.
ot

wit
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spec
es, in part or in w

t to the co
rrectness of i
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mercia

– Unplug connector -arrow-.

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For vehicles with auxiliary heater the metering pump - V54- con‐
en
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nector must be separated additionally. t. Cop py
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– Unscrew tank flap unit securing bolt and remove tank flap unit
o Vo
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⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit . Prote AG.

6. Fuel tank (Eos) 317

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Remove stiffener braces -A and B- ⇒ Running gear; Rep. gr.

42 ; Removing and installing stiffener braces .
– Remove centre and rear silencers.
– Remove heat shield for centre silencer.
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– Remove rear right wheel. lksw
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– Remove rear right wheel risehousing liner ⇒ General body re‐
d b ara
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pairs, exterior; Rep. ugr.
tho 66 ; Removing and installing wheel eo
ra
housing liner; Rearss awheel housing liner . c

ce
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itte

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ility
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– Unclip wire from filler neck -1-.

wit
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– Separate breather line -3- (only engine code CBFA, CCTA,
hole

spec
CCTB).
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t to the co
– Unbolt filler neck from body -2-.

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– Detach breather line -1- (white) behind fuel tank. Push in re‐
in t
or

taining ring to do this.

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– Engine codes CBFA, CCTA, CCTB: Detach vacuum line -2-

p

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(green) for the fuel system diagnostic pump - V144- behind

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fuel tank. Push in retaining ring to do this.
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WARNING
co lksw
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The fuel system 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.

– Disconnect breather line -1- (white) and fuel line -2- (black) at
connecting point.

Note

♦ Press in securing ring to release the fuel lines.

♦ Vehicles with auxiliary heater, the fuel line of the metering
pump - V54- must also be separated.
♦ On vehicles with engine code CBFA, CCTA, CCTB, the vac‐
uum line (green) of fuel system diagnostic pump - V144- must
also be separated.

318 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Remove securing strap and securing bolts -arrows-. When

doing this, support fuel tank with engine and gearbox jack -
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– Carefully lower fuel
ris tank.
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6.4.2 Installing fuel tank
Install in reverse order of removal. During this step, observe the

rrectne
following:
♦ To secure the securing straps for the fuel tank, only bolts with

s
loose washers must be used. If different bolts are used, the

s o
cial p

f
securing straps might twist during tightening.

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mer

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♦ Install breather lines and fuel lines free of kinks.

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♦ Do not interchange supply line and return line (return line blue,
o

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♦ Ensure that line connections are tight.

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♦ Check earth connection on fuel tank and body to filler neck.
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– Fill fuel tank with at least 5 litres of fuel.
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WARNING Prote AG.

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.

– Install stiffener braces ⇒ Running gear; Rep. gr. 42 ; Remov‐

ing and installing stiffener braces .
Specified torques:
Component Nm
Fuel tank to body - M6 bolts 10
Fuel tank to body - M8 bolts 251)
1) Renew

6. Fuel tank (Eos) 319

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

7 Repairing fuel supply (Passat, CC)

Note

♦ Fuel hoses on the engine must only be secured with spring-

type clips which conform to the production standard.
♦ Spring-type clip pliers - VAS 6499- or space saving hose clip
pliers - VAS 6362- are recommended for installation/removal
of spring-type clips.
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⇒ page 272 . ir se
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Comply with rules for cleanliness ⇒ page 274 .s au or
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Removing and installing fuel delivery unit ⇒ page 320 .
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Removing and installing fuel gauge sender - G- ⇒ page 324 .

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Check fuel pump ⇒ page 325 .
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7.1 Removing and installing fuel delivery

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unit
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Special tools and workshop equipment required
♦ Special wrench - T10202-

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320 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golfa2004 gen AG➤ , Golf 2009
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does
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4-cyl. injection engine (1.8
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Condition:

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• Fuel tank must not be more than 3/4 full. This ensures that

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the fill level is below the flange of the fuel delivery unit.

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Procedure:

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Note
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♦ When replacing fuel delivery unit, check fuel tank for heavy
soiling and clean if necessary.

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♦ Note safety precautions before beginning work ⇒ page 272 .
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♦ Observe rules for cleanliness ⇒ page 274 .

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♦ Assembly overview - fuel tank ⇒ page 275 .

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– If necessary, empty fuel tank using fuel extractor - VAS 5190-

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⇒ page 277 . C py
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– Remove bench seat ⇒ General body repairs, interior; Rep. gr. copy Vo
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Prote AG.

– Remove cover -1- with fuel pump control unit - J538- -2- from
fuel delivery unit.

– First check that connector -A- is securely seated by pulling the

connector without pressing the catch. The connector can
cause a fault if it has not been fitted correctly.
– Now pull off connector.
– Check the contacts on the connector and on the fuel delivery
unit for damage.

WARNING

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.

7. Repairing fuel supply (Passat, CC) 321

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
G. Volkswagen AG d
4-cyl. injection engine (1.8 and
ksw
a2.0
genlAengine, chain drive)
oes - Edition 02.2017
n ol ot g
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– Pull fuel line -B- off flange.orise
tee
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Note

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erm

♦ Press in securing ring to release fuel line.

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ility
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♦ On vehicles with auxiliary heater, the connector and the fuel

wit
, is n

line of the metering pump - V54- must also be disconnected.

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
– Open locking ring using key - T10202- .
l purpos

Caution

nf
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orm
Do not cant key - T10202- and press against locking ring firmly.
m

atio
m

If the key slips off, the fuel delivery unit can be damaged.
o

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or c

thi
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sd
a

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iv

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– Lift flange.
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– Separate coupling -A- and remove suction-jet pump -B-. Do
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this by pressing lugs -arrows- together.

Note

Press in safety ring of coupling -A- to release fuel line.

– Pull seal and fuel delivery unit out of opening of fuel tank.

Note

♦ If delivery unit is to be renewed, drain old delivery unit before

disposal.
♦ Observe disposal regulations!

Install fuel delivery unit:

Caution

Do not bend float arm of fuel gauge sender - G- when installing.

– Insert fuel delivery unit (without suction-jet pump) into fuel

tank.

322 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Install suction-jet pump -B- and reconnect coupling -A-. Check

coupling is secured properly by pulling.

– Push flange onto fuel delivery unit.

Note

Ensure hoses are secured correctly.

cardiagn.com
– Now pull seal -A- over the flange and seat it in the opening of
the fuel tank.
– Moisten seal lightly with fuel and push flange into fuel tank.

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– Observe installation position: Marking -A- points towards rear

du

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of vehicle.
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erm

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– Tighten locking ring using wrench - T10202- . Torque setting

ot p

wit

⇒ Item 16 (page 276) .

, is n

h re
hole

The remaining installation steps are carried out in the reverse or‐
spec

der of removal. During this step, observe the following:

es, in part or in w

t to the co
rrectness of i
l purpos

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7. Repairing fuel supply (Passat, CC)
 AG. Volkswagen AG d
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CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf aut 2009 ➤ , Passat 2006 ➤ , ...
ho eo
ra
4-cyl. injection engine (1.8 and 2.0 l engine,
s chain drive) - Edition 02.2017
s c

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♦ The -arrow- on the cover points forwards.

itte

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♦ Fuel lines are to be installed free of kinks.

ility
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♦ Ensure wiring/line connections are secured properly by pulling

h re
back.

ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
7.2 Removing and installing fuel gauge
mer

atio
m

sender - G-
o

n
c

i
or

n thi
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♦ Note safety precautions before beginning work ⇒ page 272 .
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♦ Observe rules for cleanliness ⇒ page 274 . yri
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♦ Assembly overview - fuel tank ⇒ page 275 .
agen
Prote AG.

Removing fuel gauge sender

– Remove fuel delivery unit ⇒ page 320 .
– Pull fuel gauge sender - G- slightly to side and upwards at the
same time.

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

-arrows- must also be pushed to the side slightly.
– Note colour co-ordination of cables for reinstallation.

324 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Release electrical connectors -1 to 3- and pull them off. Then

bend back locking lugs of connectors.
Installing:

– Connect connectors -1…3-. Observe colour co-ordination.

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– Check connectors are
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– Insert fuel gauge
tho
ris sender - G- into guide on fuel delivery unit
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and press sdown
au until it engages. ra
c
s

ce
le

– Install fuel delivery unit ⇒ page 322 .

un

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rm

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ab
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ot

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h re
hole

spec
es, in part or in w

t to the co
7.3 Checking fuel pump
rrectness of i

Note
l purpos

When replacing fuel delivery unit, check fuel tank for heavy soiling
nform
ercia

and clean if necessary.

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7. Repairing fuel supply (Passat, CC) 325

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

Special tools and workshop

equipment required
♦ Pressure gauge - VAS
6550-
♦ Remote control - V.A.G
1348/3A-
♦ Test instrument adapter/
DSO (5-pin) - VAS 5565-
♦ Multimeter - V.A.G 1715-
♦ Special wrench - T10202-
♦ Measuring container, ca‐
pacity at least 3 litres

cardiagn.com
AG. Volkswagen AG d
agen oes
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7.3.1 Checking function and voltage supply

wit
is n

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ole,

• Battery voltage at least 11.5 V.

spec
urposes, in part or in wh

• Fuse for fuel pump on fuse holder OK ⇒ Current flow diagrams,

t to the co
Electrical fault finding and Fitting locations.
• Fuel pump control unit - J538- OK.
rrectne

Note
ss o
cial p

f in

♦ Function of fuel pump is checked using final control diagnosis.

form
mer

atio

♦ If the final control diagnosis is to be carried out several times

om

in succession, it may be necessary to start the engine briefly

n
c

i
or

before repeating the final control diagnosis.

thi
te

sd
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pr

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en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

326 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Connect vehicle diagnostic tester as follows:

– Push diagnosis cable connector onto diagnosis connection in
driver footwell.
– Switch ignition on.
– Press buttons on display one after the other for Vehicle
self-diagnosis , Engine electronics and Final con-
trol diagnosis .

– Press right arrow button ► on display up to final control diag‐

nosis for fuel pump electronics.
The fuel pump must now run slowly up to maximum speed.

Note

The fuel pump runs very quietly.

– Switch off ignition. agen

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If fuel pump does not run: byV gu
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or eo
– Remove bench seat ⇒ General aut body repairs, interior; Rep. gr.
h
ra
72 ; Removing and installings bench seat .
s c

ce
e
nl

pt
du

an
– Pull connector off fuel pump control unit - J538- .
itte

y li
erm

ab
ility
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wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

– Check voltage supply between contacts -1- and -6- using mul‐
rm
m

timeter - V.A.G 1715- .

atio
om

n in
c

• Specification: approx. battery voltage

or

thi
te

sd
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Voltage supply not OK:

iv

o
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rp

cu
o

– Locate and eliminate open circuit referring to current flow di‐

f

en
ng

t.
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agram ⇒ Current flow diagrams, Electrical fault finding and
Co
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Fitting locations.
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Voltage supply OK:
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Prote AG.

7. Repairing fuel supply (Passat, CC) 327

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Remove cover -1- with fuel pump control unit - J538- -2- from
fuel delivery unit.

– First check that connector -A- is securely seated by pulling the

connector without pressing the catch. If connector was not in‐
serted correctly, repeat functional check of fuel pump.
– Now pull off connector.
– Check the contacts on the connector and on the fuel delivery
unit for damage.

cardiagn.com
WARNING

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.

– Pull off fuel line -B- from the flange.

Note

♦ Press in securing ring to release fuel line. agen

AG. Volkswagen AG d
oes
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♦ On vehicles with auxiliary heater, the connector ed band the fuel ara
nte
ris
line of the metering pump - V54- must alsothobe disconnected. eo
au ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

– Open locking ring using key - T10202- .

wit
, is n

h re
hole

spec

Caution
es, in part or in w

t to the co

Do not cant key - T10202- and press against locking ring firmly.
If the key slips off, the fuel delivery unit can be damaged.
rrectness of i
l purpos

– Check that electrical wires between flange and fuel pump are
connected.
nform
ercia

If no open circuit can be found:

m

at
om

– Fuel pump defective, renew fuel delivery unit ⇒ page 320 .

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or

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ate

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for

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Cop py
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328
by c lksw
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Rep. gr.20 - Fuel supply system
agen
Prote AG.
 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

7.3.2 Checking fuel pressure

Test conditions:
• Function of fuel pump has been checked ⇒ page 326 .
Test sequence

Note

♦ The fuel pressure must be checked by means of the final con‐

trol diagnosis. If the fuel pressure is measured at idling speed,
it may deviate from the specification. G. Volkswagen nA AG do
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♦ If the final control diagnosis is to be carried
y Vout several times
olks ot g
in succession, it may be necessary toisstart
ed
b
the engine briefly ua
ran
before repeating the final control diagnosis.
ut
hor tee
or
a ac
ss

ce
Note safety precautions before beginning work ⇒ page 272 .
e
nl

pt
du

an
itte

– Observe rules for cleanliness ⇒ page 274 .

y li
erm

ab
ility
ot p

WARNING

wit

cardiagn.com
, is n

h re
hole

spec
Fuel supply line is pressurised. Wear protective goggles and
es, in part or in w

protective clothing to avoid injury and contact with the skin.

t to the co
Wrap a cloth around the connection before loosening hose
connections. Then release pressure by carefully pulling hose
off connection.

rrectness of i
l purpos

– Pull off supply line (metal coupling) -arrow- and catch escaping
fuel with a cloth.

nf
ercia

orm
m

atio
m

Note
o

n in
or c

thi
e

Press in securing ring to release fuel line.

t

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
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cted agen
Prote AG.

7. Repairing fuel supply (Passat, CC) 329

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Connect pressure tester - VAS 6550- to fuel supply line with

adapter - VAS 6550/1- and -VAS 6550/2- .
– Make sure that drain tap is closed and cut-off taps are open.
– Actuate fuel pump with final control diagnosis to build up fuel
pressure.
– Read fuel pressure on pressure gauge. AG. Volkswagen AG d
agen oes
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• Specification: 4.0 to 7.0 bar byV
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If fuel pressure is OK, check holding pressure
ut
hor
⇒ page 332 . eo
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If the specification is exceeded: s

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le
un

pt
– Pressure limiting valve in flange defective, renew flange with

an
d
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fuel filter ⇒ Item 15 (page 276) .
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pe

ility
If specification is not obtained
ot

wit
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h re
– Check fuel lines for possible restrictions (kinks) or blockages.
hole

spec
If no fault is found:
es, in part or in w

t to the co
– Renew flange with fuel filter and pressure limiting valve
⇒ Item 15 (page 276) .

cardiagn.com
rrectness of i
– Repeat check.
l purpos

If reading again does not match specification:

– Fuel pump defective, renew fuel delivery unit ⇒ page 320 .

nform
mercia

7.3.3 Checking fuel pressure when the engine

a
com

tion in
is running (engine codes CCZA, CCZB,
r
te o

thi
CDAA, CDAB)

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iva

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cum
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t.
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Note Cop py
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♦ If a complaint is made about the vehicle's performance, the
co Vo
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reason may be that the fuel pressure is too low. Faults in the Prote AG.
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 lowest fuel
pressure is measured by the pressure tester - VAS 6550- and
reported to the vehicle diagnosis and service information sys‐
tem - VAS 5052 B- .
♦ 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 diagnosis and service information system -
VAS 5052 B- by means of “Functions and component
selection”.

Special tools and workshop equipment required

♦ Pressure gauge - VAS 6550-
♦ Hose adapters - VAS 6550/1- and -VAS 6550/2-
♦ Vehicle diagnosis and service information system - VAS 5052
B-
♦ Connector cable - VAS 5051/66-
– Remove bench seat ⇒ General body repairs, interior; Rep. gr.
72 ; Removing and installing bench seat .

330 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Remove cover -1- with fuel pump control unit - J538- -2- from
fuel delivery unit.

– First check that connector -A- is securely seated by pulling the

connector without pressing the catch. wThe genconnector
AG. Volkswagcan
en AG
does
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cause a fault if it has not been fitted
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WARNING au ac
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The fuel line is under pressure.

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Fuel poses danger of injury to eyes and skin.

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rm

ab
pe

ility
Wear protective goggles and protective clothing to avoid injury
ot

wit
, is n

and contact with the skin. Wrap a cloth around the connection

h re
hole

before loosening hose connections. Then reduce pressure by

spec
carefully opening the connection.
es, in part or in w

t to the co
– Pull off supply line -arrow- and catch escaping fuel with a cloth.

rrectness of i
l purpos

Note
nform
ercia

Press in securing ring to release fuel line.

m

a
com

tion in
r
te o

thi
s
iva

do
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rp

cum
fo

en
ng

t.
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Cop py
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Prote AG.

7. Repairing fuel supply (Passat, CC) 331

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Connect pressure tester - VAS 6550- to fuel supply line with

adapter - VAS 6550/2- and -VAS 6550/1- .
– Fit connector cable - VAS 5051/66- to pressure tester - VAS
6550- and to vehicle diagnosis and service information system
- VAS 5052 B- .
– Make sure that drain tap is closed and cut-off taps are open.
– Switch on pressure tester - VAS 6550- .
If the fuel pressure test is carried out within “Guided Fault Find‐
ing”, follow the instructions of the diagnostic tester.
If the fuel pressure test is carried out without “Guided Fault Find‐
ing”, proceed as follows:
– Connect vehicle diagnosis and service information system -
VAS 5052 B- to vehicle.
– Select Guided Fault Finding in -VAS 5052 B- .
– Carry out identification of vehicle.
– Using the GoTo button, select the following menu options one
after the other:

cardiagn.com
♦ Function/component selection
♦ Drive
♦ Engine
♦ 24 Mixture preparation/injection
♦ Mechanical components
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♦ High-pressure pump byV
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– Follow instructions on vehicle diagnosis andutservice
ho informa‐ or
tion system - VAS 5052 B- . ss
a ac

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WARNING an
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Test instruments and measuring equipment must always be wit

secured to the rear seat and operated by a second person from
, is n

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this location.
hole

spec
es, in part or in w

t to the co

7.3.4 Checking holding pressure

rrectness of i
l purpos

Note

If the final control diagnosis is to be carried out several times in

nform
ercia

succession, it may be necessary to start the engine briefly before

m

repeating the final control diagnosis.

at
om

ion
c

in t
or

his
ate

do
priv

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for

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ng

t.
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Cop py
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by
cted agen
Prote AG.

332 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

Prerequisites for check

• Fuel pressure OK and pressure tester - VAS 6550- connected.
Check fuel pressure ⇒ page 329 .
Test sequence
– Actuate fuel pump with final control diagnosis to build up fuel
pressure.
– Read fuel pressure on pressure gauge.
• Specification: 4.0 to 7.0 bar
– End self-diagnosis, and switch off ignition.
– Watch pressure drop on pressure gauge. Pressure must re‐
main above 3.0 bar for 10 minutes.
If the pressure drops further:
– Actuate fuel pump with final control diagnosis to build up fuel
pressure.

– After pressure has built up, close cut-off tap -B- of pressure
tester immediately. Lever is then at right angle to direction of

cardiagn.com
flow.
If the pressure drops again (leak on fuel tank side):
Leak must be sought on fuel tank side; proceed as follows:
– Check fuel line to flange ⇒ Item 15 (page 276) for leaks.
If no fault is found on the fuel line: agen
AG. Volkswagen AG d
oes
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Pressure limiting valve in flange defective or pressure retention
d by gu
ara
valve in fuel pump leaking. rise nte
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– First replace flange with fuel filter ⇒ Item 15 (page
ss 276) and c
repeat pressure retention check. If leak is still present, renew

ce
e
nl

pt
du

fuel delivery unit.

an
itte

y li
erm

ab
If the pressure does not drop now (leak on engine side):

ility
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wit
, is n

h re
Note
hole

spec
es, in part or in w

t to the co
Search for leak on engine side. Repeat holding pressure test. This
time, close shut-off tap -A- to check whether leak actually is on
engine side.
rrectness of i
– If there is a leak on the engine side, carry out external check
l purpos

of the fuel pipes and high-pressure pump for leaks.

If no fault can be determined, check the injectors for leaks:
nf
ercia

orm

– Remove spark plugs. Open shut-off valves -A- and -B-. Ac‐
m

atio
m

tuate fuel pump with final control diagnosis.

o

n in
or c

– Check through spark plug holes whether fuel has collected on

thi
te

sd
a

the piston crown due to a leaking injector.

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f

en
ng

7.3.5 Checking fuel delivery rate (engine co‐

t.
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Test conditions:
• Filling level in fuel tank above reserve

7. Repairing fuel supply (Passat, CC) 333

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine,
wage chain drive) - Edition
n AG. Volkswagen AG do
e 02.2017 ks s no
Vol t gu
by ara
Test sequence ris
ed
nte
utho eo
– Remove bench seat ⇒ Generalssbody
a repairs, interior; Rep. gr. ra
c
72 ; Removing and installing bench seat .

ce
le
un

pt
an
d
– Remove cover -1- with fuel pump control unit - J538- -2- from

itte

y li
fuel delivery unit.

rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
ercia

– First check that connector -A- is securely seated by pulling the

connector without pressing the catch. The connector can
m

a
com

ti
cause a fault if it has not been fitted correctly.

on in
r
te o

thi
– Now pull off connector.

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s
iva

do
r
rp

– Check the contacts on the connector and on the fuel delivery

cum
fo

unit for damage.

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– 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.

WARNING

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.

334 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
agen4-cyl. injectionAengine
oes (1.8 and 2.0 l engine,
chain drive) - Edition 02.2017
AG. Volkswagen G d
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– Pull off supply d b line (metal coupling) -arrow- and catchara
rise nteescaping
fuel with thoa cloth. eo
s au ra
c
s

ce
le
un

pt
Note

an
d
itte

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ab
Press in securing ring to release the fuel lines.
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
– Connect pressure tester - VAS 6550- to fuel supply line with
adapter - VAS 6550/2- . Hold adapter - VAS 6550/1- in a
l purpos

measuring container.
– Make sure that drain tap is closed and cut-off taps are open.

nform
mercia

a
com

ti
WARNING

on in
r
te o

thi

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Danger of spray when shut-off tap is opened. Wear eye pro‐

s
iva

do
r

tection and protective clothing to avoid injuries and skin con‐

rp

cum
fo

tact. Hold container in front of open connection of pressure

en
ng

t.
tester.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
– Operate remote control - V.A.G 1348/3A- . Then slowly close
Prote
cted AG.
agen
shut-off tap -arrow- until a pressure of 4 bar is displayed on
pressure gauge. From this point on do not move position of
shut-off tap.
– Drain measuring container.

– The quantity delivered by the fuel pump depends on the bat‐

tery voltage. Therefore, connect multimeter - V.A.G 1715- to
wires -1- and -5- of adapter - VAS 5565- in addition.
– Operate remote control for 60 seconds while measuring volt‐
age at fuel pump.

7. Repairing fuel supply (Passat, CC) 335

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Compare quantity of fuel delivered with specification.

*) Minimum delivery rate cm³/60 s
**) Voltage at fuel pump with engine 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 cm³/60 s
If specification is not obtained
– Check fuel line for possible restrictions (kinks) or blockages.
If no fault is found:
– Remove cap from fuel filler neck and repeat check. If fuel de‐
livery rate is now reached, check fuel tank breather.
If reading again does not match specification:
– Remove fuel delivery unit and check filter strainer for soiling.
– If no fault is found here either, renew flange with fuel filter.
– Repeat check.

cardiagn.com
If reading again does not match specification:
– Fuel pump defective, renew fuel delivery unit ⇒ page 320 .
If the fuel delivery rate has been attained but a fault is still sus‐
pected in the fuel supply system (e.g. intermittent failure of fuel
supply system):
– Measure current draw of fuel pump ⇒ page 338 .

7.3.6 Checking fuel delivery rate (engine co‐

des CCZA, CCZB, CDAA, CDAB) agen
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The fuel delivery rate must first be checked in the engine com‐ ce
le
un

pt
partment with the help of the function “Checking fuel delivery rate, an
d
itte

quick test”. If the minimum delivery rate is not achieved, a 2nd y li

rm

ab
measurement must be carried out at the flange of the fuel delivery
pe

ility
unit.
ot

wit
, is n

h re
hole

Checking fuel delivery rate in engine compartment:

spec
es, in part or in w

– Connect vehicle diagnosis and service information system -

t to the co

VAS 5052 B- to vehicle.

– Select Guided Functions in -VAS 5052 B- .
rrectness of i

– Carry out identification of vehicle.

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– Select Engine .
nform
ercia

– Select Checking fuel delivery rate, quick test .

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– Follow instructions on vehicle diagnosis and service informa‐

tion in

tion system - VAS 5052 B- .

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Checking fuel delivery rate at flange:

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Test conditions:
en
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• The guided function “Checking fuel delivery rate, quick test” Cop py
ht. rig
has been carried out ⇒ Vehicle diagnostic tester rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

336 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

• The remote control - V.A.G 1348/3A- and test instrument

adapter/DSO (5-pin) - VAS 5565- have been connected to the
fuel delivery unit.
• Battery charger connected
• Filling level in fuel tank above reserve
Test sequence

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
n AG. Volkswagen AG do
carefully opening the connection. olks
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– Pull supply line -arrow- off at flange and
s au catch escaping fuel ra
c
with a cloth. s

ce
e

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nl

pt
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itte

y li
erm

Note

ab
ility
ot p

wit
, is n

Press in securing ring to release the fuel lines.

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Connect pressure tester - VAS 6550- to flange with adapter -

VAS 6550/2- . Hold adapter - VAS 6550/1- in a measuring
container.

nf
ercia

orm
– Make sure that drain tap is closed and cut-off taps are open.
m

atio
om

– Press the remote control - V.A.G 1348/3A- and slowly close n in

or c

thi

shut-off tap -arrow- until a pressure of 4 bar is displayed on

te

sd
a

pressure gauge. From this point on do not move position of

iv

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shut-off tap.
o

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f

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t.
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– Drain measuring container.
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– The quantity delivered by the fuel pump depends on the bat‐

tery voltage. Therefore, connect multimeter - V.A.G 1715- to
wires -1- and -5- of adapter - VAS 5565- in addition.
– Operate remote control for 60 seconds while measuring volt‐
age at fuel pump.

7. Repairing fuel supply (Passat, CC) 337

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Compare quantity of fuel delivered with specification.

*) Minimum delivery rate cm³/60 s
**) Voltage at fuel pump with engine 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 cm³/60 s
If specification is not obtained
– Remove cap from fuel filler neck and repeat check. If fuel de‐
livery rate is now reached, check fuel tank breather.
If reading again does not match specification:
– Remove fuel delivery unit and check filter strainer for soiling.
– If no fault is found here either, renew flange with fuel filter.
– Repeat check.
If reading again does not match specification:
– Fuel pump defective, renew fuel delivery unit ⇒agpage
en AG320
. Volks. wagen AG

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If fuel delivery rate has been attained, butednevertheless
by
V
you sus‐ ua
ran
pect a fuel supply system fault (e.g. intermittent
oris failure of fuel tee
th
supply system): Check fuel pressureauwith the engine running or
ac
⇒ page 330 . ss

ce
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7.3.7 Checking current consumption

y li
erm

ab
ility
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– Remove bench seat ⇒ General body repairs, interior; Rep. gr.

wit
is n

72 ; Removing and installing bench seat .

h re
ole,

spec
– Remove cover -1- with fuel pump control unit - J538- -2- from
urposes, in part or in wh

fuel delivery unit.

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

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or

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– First check that connector -A- is securely seated by pulling the

p

cum
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connector without pressing the catch. The connector can

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ng

t.
cause a fault if it has not been fitted correctly.
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Cop py
ht. rig
– Now pull off connector. rig ht
py by
co Vo
by lksw
– Check the contacts on the connector and on the fuel delivery cted agen
Prote AG.
unit for damage.

338 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

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

connector and fuel delivery unit.
– Connect pick-up clamp -A- to red terminal with lettering “pick-
up clamp” for test instrument adapter/DSO (5-pin) - VAS
5565- .
– Start engine and run at idling speed.
– Measure current draw of fuel pump.
• Specification: max. 10 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 not always evident, the check
G. Volkswage
can also be carried outksw
during
agen
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a road test. A 2nd
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If the ut
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ac
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– Fuel pump defective, renew fuel delivery unit ⇒ page 320 .
e
nl

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ab
ility
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es, in part or in w

t to the co
rrectness of i
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mercia

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ion
c

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or

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ate

do
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cum
for

en
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t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

7. Repairing fuel supply (Passat, CC) 339

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

8 Repairing fuel supply system (Golf,

Eos, Scirocco)

Note

♦ Fuel hoses on the engine must only be secured with spring-

type clips which conform to the production standard.
♦ Spring-type clip pliers - VAS 6340- or space saving hose clip
pliers - VAS 6362- are recommended for installing and remov‐
ing spring-type clips.

Safety precautions when working on fuel supply system

⇒ page 272 .
Comply with rules for cleanliness ⇒ page 274 .
Removing and installing fuel delivery unit ⇒ page 340 .
. Volkswagen AG
gen AG d
Removing and installing fuel Vgauge
olks
wa sender - G- ⇒ pageoe343
s no .
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Checking fuel pump - G6-
ise ⇒ page 344 .

cardiagn.com
nte
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8.1 Removing
ss and installing fuel delivery c
ce
e

unit
nl

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Special tools and workshop equipment required
erm

ab
ility
ot p

♦ Special wrench - T10202-

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
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orm
m

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om

n in
or c

♦ Torque wrench (40 to 200 Nm) - V.A.G 1332-

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

340 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

Removing:

Caution

Condition:
• 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

♦ When replacing fuel delivery unit, check fuel tank for heavy
soiling and clean if necessary.
♦ If necessary, drain fuel tank using fuel extractor - VAS 5190- .
♦ Note safety precautions before beginning work ⇒ page 272 .
G. Volkswagen AG d
♦ Observe rules for cleanliness ⇒ page 274
lksw
agen.
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♦ Assembly overview - fuel tank ised⇒ page 285 .
b ara
nte

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or eo
h
aut ra
– Remove bench seat ⇒ General
ss body repairs, interior; Rep. gr. c

ce
72 ; Removing and installing bench seat .
le
un

pt
an
d
itte

– Remove cover -1- with fuel pump control unit - J538- -2- from

y li
erm

ab
fuel delivery unit.

ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

– First check that the connector -arrow- is fitted securely by pull‐

atio

ing the connector without pressing the catch. The connector

om

can cause a fault if it has not been fitted correctly.

c

i
or

n thi
e

– Now pull off connector.

t

sd
iva

o
pr

cum
r

– Check the contacts on the connector and on the fuel delivery

fo

en
ng

unit for damage.

t.
yi Co
Cop py
ht. rig
rig ht
WARNING
py by
co Vo
by lksw
cted agen
Prote AG.
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.

8. Repairing fuel supply system (Golf, Eos, Scirocco) 341

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Pull fuel lines -1- and -2- off the flange.

Note

♦ Press in securing ring to release the fuel lines.

♦ On vehicles with auxiliary heater, the connector and the fuel
line of the metering pump - V54- must also be disconnected.
n AG. Volkswagen AG age does
ksw not
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au ra
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ss

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– Open locking ring using key - T10202- and raise flange slightly.

an
itte

y li
erm

ab
ility
ot p

Caution

wit
, is n

h re
Do not cant key - T10202- and press against locking ring firmly.
hole

spec
If the key slips off, the fuel delivery unit can be damaged.
es, in part or in w

t to the co

cardiagn.com
– Pull fuel delivery unit and seal out of the opening in fuel tank.

rrectness of i
l purpos

Note

♦ If delivery unit is to be renewed, drain old delivery unit before nform

ercia

disposal.
m

at
om

♦ Observe disposal regulations!

on
c

in t
or

his
ate

Installing:
do
priv

cum
or

– Fit gasket.
f

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ng

t.
yi Co
op
– Insert seal for fuel delivery unit dry into opening of fuel tank. C py
t. rig
gh ht
yri by
– Coat inner side of seal with fuel. op Vo
by c lksw
cted agen
Prote
– When inserting fuel delivery unit, ensure that fuel gauge send‐
AG.

er is not bent.

– Press sealing flange down against spring pressure, and move

sealing flange to installation position.
• Tab -2- on flange must be between lugs -1- and -3- on fuel
tank.
• -Arrow- points in direction of travel.
– Tighten sealing flange.
• Specified torque: 110 Nm

342 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Reconnect supply line-1- (black). agen

AG. Volkswagen AG d
oes
olksw not
V gu
– Reconnect fuel return line -2- (blue or ed blue marking).
by ara
nte
ris
ho eo
aut ra
ss c

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un

pt
an
d
itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
– Reconnect connector -arrow-.

rrectne
– Ensure push-fit couplings and electrical connectors are se‐
cured properly by pulling.

ss
Further assembly is performed in the reverse order of removal.

o
cial p

f
During this step, observe the following:

inform
mer

atio
m

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o

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
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Cop py
♦ Observe installation position of fuel feed line to auxiliary heater ht. rig
rig ht
⇒ Auxiliary heater; Rep. gr. 82 ; Fuel feed Thermo Top V .
py by
co Vo
by lksw
cted agen
♦ The -arrow- on the cover points forwards.
Prote AG.

8.2 Removing and installing fuel gauge

sender - G-
Removing:
– Remove fuel delivery unit ⇒ page 340 .
– Pull fuel gauge sender - G- slightly to side and upwards at the
same time.

8. Repairing fuel supply system (Golf, Eos, Scirocco) 343

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017
AG . Volkswage
– If the sender cannot be released
ksw
agenin this way, theAG
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retaining
does
not
tabs
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-arrows- must also be bpushed
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o to the side slightly. gu
a d ran
ise
– Note colour co-ordination
ut
ho
r
of cables for reinstallation. tee
or
a ac
ss

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an
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itte

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ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
– Release electrical connectors -1 to 3- and pull them off. Then
bend back locking lugs of connectors.

rrectness of i
Installing:
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mercia

a
com

tio

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n in
r
te o

thi
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do
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cum
fo

en
ng

t.
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Cop py
t. rig
– Connect connectors -1…3-. Observe colour co-ordination. gh ht
pyri by
Vo
co lksw
by
– Check connectors are secured properly by pulling. Prote
cted AG.
agen

– Insert fuel gauge sender - G- into guide on fuel delivery unit

and press down until it engages.
– Install fuel delivery unit ⇒ page 340 .

8.3 Checking fuel pump - G6-

344 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

Special tools and workshop

equipment required
♦ Pressure gauge - VAS
6550-
♦ Remote control - V.A.G
1348/3A-
♦ Test instrument adapter/
DSO (5-pin) - VAS 5565-
♦ Multimeter - V.A.G 1715-
♦ Special wrench - T10202-
♦ Torque wrench - V.A.G
1332-
♦ Measuring container, ca‐
pacity: 3 litres

cardiagn.com
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
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aut ra
ss c

ce
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nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

8.3.1 Checking function and voltage supply

rrectness of i

Test conditions:
l purpos

• Battery voltage at least 11.5 V.

• Fuse for Fuel pump control unit - J538- OK.
nf
ercia

• Fuel pump control unit - J538- OK.

rm
m

atio
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Test sequence
o

n in
or c

thi
te

sd
iva

Note
r
rp

cu
o

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f

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ng

t.
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♦ Function of fuel pump is checked using final control diagnosis.
Co
Cop py
t. rig
gh
♦ If the final control diagnosis is to be carried out several times
ht
pyri by
Vo
in succession, it may be necessary to start the engine briefly
o
by c lksw
cted agen
before repeating the final control diagnosis. Prote AG.

8. Repairing fuel supply system (Golf, Eos, Scirocco) 345

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Connect vehicle diagnostic tester as follows:

– Push diagnosis cable connector onto diagnosis connection in
driver footwell.
– Switch ignition on.
– Press buttons on display one after the other for Vehicle
self-diagnosis , Engine electronics and Final con-
trol diagnosis .

– Press right arrow button ► on display up to final control diag‐

nosis for fuel pump electronics.
The fuel pump must now run slowly up to maximum speed.

Note

The fuel pump runs very quietly.

– Switch off ignition.

If fuel pump does not run:

cardiagn.com
– Remove bench seat ⇒ General body repairs, interior; Rep. gr.
72 ; Removing and installing bench seat .

– Pull connector off fuel pump control unit - J538- .

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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aut ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

– Check voltage supply between contacts -1- and -6- using mul‐ t to the co
timeter - V.A.G 1715- .
• Specification: approx. battery voltage
rrectness of i

Voltage supply not OK:

l purpos

– Locate and eliminate open circuit referring to current flow di‐

agram ⇒ Current flow diagrams, Electrical fault finding and
nform
ercia

Fitting locations.
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com

Voltage supply OK:

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

346 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Remove cover -1- with fuel pump control unit - J538- -2- from
fuel delivery unit.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
– First check that the connector -arrow- is fitted securely by pull‐
hole

spec
ing the connector without pressing the catch. If connector was es, in part or in w
not inserted correctly, repeat functional check of fuel pump.

t to the co
– Now pull off connector.
– Check the contacts on the connector and on the fuel delivery

rrectness of i
unit for damage.
l purpos

cardiagn.com
WARNING

nf
ercia

orm
Fuel supply line is pressurised. Wear protective goggles and
m

atio
m

protective clothing to avoid injury and contact with the skin.

o

n in
c

Wrap a cloth around the connection before loosening hose

or

thi
e

connections. Then release pressure by carefully pulling hose

t

sd
iva

off connection.

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
– Pull fuel lines -1- and -2- off the flange. gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note

♦ Press in securing ring to release the fuel lines.

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

– Open locking ring using key - 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.

– Check that electrical wires between flange and fuel pump are
connected.
If no open circuit can be found:
– Fuel pump defective, renew fuel delivery unit ⇒ page 340 .

8. Repairing fuel supply system (Golf, Eos, Scirocco) 347

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

8.3.2 Checking fuel pressure

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♦ The fuel pressureorise
must be checked by means of the final
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h
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WARNING

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es, in part or in w

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Fuel supply line is pressurised. Wear protective goggles and
protective clothing to avoid injury and contact with the skin.
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rrectness of i
connections. Then release pressure by carefully pulling hose
off connection.
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– Pull off supply line (metal coupling) -arrow- and catch escaping

or
fuel with a cloth.
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Press in securing ring to release fuel line.

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– Connect pressure tester - VAS 6550- to fuel supply line with

adapter - VAS 6550/1- and -VAS 6550/2- .
– Make sure that drain tap is closed and cut-off taps are open.
– Actuate fuel pump with final control diagnosis to build up fuel
pressure.
– Read fuel pressure on pressure gauge.
• Specification: 4.0 to 7.0 bar
If fuel pressure is OK, check holding pressure ⇒ page 352 .
If the specification is exceeded:
– Check return line between fuel filter and fuel pump for kinks
and blockages.
If no fault is found:
– Pressure limit valve in fuel filter is defective. Renew fuel filter.
If specification is not obtained
– Check fuel pressure upstream of fuel filter; proceed as follows:

348 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , gGolf n AG2009 ➤ag,ePassat
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– Pull fuel supply line -arrow- off fuel filter. tho
or
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– Connect pressure tester - VAS 6550- between fuel filter and

s
fuel supply line with adapter - VAS 6550/1- and -VAS 6550/2- .

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– Make sure that drain tap is closed and cut-off taps are open.
– Switch ignition on and activate the fuel pump with the final
control diagnosis function.
– While the fuel pump is operating, close the shut-off tap -A-.
Pressure must rise to at least 7.0 bar. When 7.0 bar is reached,
open shut-off tap again immediately.
If pressure has risen:
– Fuel pump is OK. Pressure limiting valve in fuel filter is defec‐
tive. Renew fuel filter.
If pressure does not rise:
– Fuel pump defective, renew fuel delivery unit ⇒ page 340 .

8. Repairing fuel supply system (Golf, Eos, Scirocco) 349

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

8.3.3 Checking fuel pressure when the engine

is running (engine codes CCZA, CCZB,
CDAA, CDAB)

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 lowest fuel
pressure is measured by the pressure tester - VAS 6550- and
reported to the vehicle diagnosis and service information sys‐
tem - VAS 5052 B- .
♦ This test can be part of “Guided Fault Finding” if an entry has
agen
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♦ Pressure gauge - VAS 6550-
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♦ Hose adapters - VAS 6550/1- and -VAS 6550/2-

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♦ Vehicle diagnosis and service information system - VAS 5052

spec
B-
es, in part or in w

t to the co
♦ Connector cable - VAS 5051/66-
– Remove bench seat ⇒ General body repairs, interior; Rep. gr.

rrectness of i
72 ; Removing and installing bench seat .
l purpos

– Remove cover -1- with fuel pump control unit - J538- -2- from
fuel delivery unit.

nform
mercia

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tion in
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te o

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– First check that the connector -arrow- is fitted securely by pull‐
ing the connector without pressing the catch. The connector
can cause a fault if it has not been fitted correctly.

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.

350 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Pull off supply line -arrow- and catch escaping fuel with a cloth.

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Press in securinghor ring to release fuel line.
is tee
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ss

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– Connect pressure tester - VAS 6550- to fuel supply line with
urposes, in part or in wh

adapter - VAS 6550/2- and -VAS 6550/1- .

t to the co
– Fit connector cable - VAS 5051/66- to pressure tester - VAS
6550- and to vehicle diagnosis and service information system

rrectne
- VAS 5052 B- .
– Make sure that drain tap is closed and cut-off taps are open.

ss o
cial p

– Switch on pressure tester - VAS 6550- .

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inform
mer

If the fuel pressure test is carried out within “Guided Fault Find‐

atio
ing”, follow the instructions of the diagnostic tester.
om

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If the fuel pressure test is carried out without “Guided Fault Find‐
thi
e

ing”, proceed as follows:

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– Connect vehicle diagnosis and service information system -

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fo

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VAS 5052 B- to vehicle.

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– Select Guided Fault Finding in -VAS 5052 B- .
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– Carry out identification of vehicle.
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– Using the GoTo button, select the following menu options one
after the other:
♦ Function/component selection
♦ Drive
♦ Engine
♦ 24 Mixture preparation/injection
♦ Mechanical components
♦ High-pressure pump
– Follow instructions on vehicle diagnosis and service informa‐
tion system - VAS 5052 B- .

WARNING

Test instruments and measuring equipment must always be

secured to the rear seat and operated by a second person from
this location.

8. Repairing fuel supply system (Golf, Eos, Scirocco) 351

 AG. Volkswagen AG d
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8.3.4 Checking holding pressure

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• Fuel pressure OK and pressure tester - VAS 6550- connected.

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Check fuel pressure ⇒ page 348 .

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– Actuate fuel pump with final control diagnosis to build up fuel

spec
pressure.
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– Read fuel pressure on pressure gauge.
• Specification: 4.0 to 7.0 bar

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– End self-diagnosis, and switch off ignition.
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– Watch pressure drop on pressure gauge. Pressure must re‐

main above 3.0 bar for 10 minutes.

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If the pressure drops further:

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– Actuate fuel pump with final control diagnosis to build up fuel

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pressure.
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– After pressure has built up, close cut-off tap -B- of pressure

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tester immediately. Lever is then at right angle to direction of

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If the pressure does not drop now (leak on engine side) py by
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⇒ page 353 .
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If the pressure drops again (leak on fuel tank side):
Leak must be sought on fuel tank side; proceed as follows:
– Check fuel supply line to fuel filter for leaks.
If no fault is found on the fuel line:
– Check pressure retention valve in fuel delivery unit. Proceed
as follows:

– Pull fuel supply line -arrow- off fuel filter.

352 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

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

fuel supply line with adapter - VAS 6550/1- and -VAS 6550/2- .
– Make sure that drain tap is closed and cut-off taps are open.
– Actuate fuel pump with final control diagnosis to build up fuel
pressure.
– Read fuel pressure on pressure gauge.
• Specification: 4.0 to 7.0 bar

– After pressure has built up, close cut-off tap -A-. n AG. Volkswagen AG do
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– Watch pressure drop on pressure gauge. Pressure ed
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– Pressure retention valve in fuel pump defective; renew fuel
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delivery unit ⇒ page 340 .

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If the pressure does not drop:

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– Pressure retention valve in fuel filter is OK, pressure limiting

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hole

valve in fuel filter is defective. Renew fuel filter.

spec
es, in part or in w

If the pressure does not drop now (leak on engine side):

t to the co
Note

rrectness of i
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Search for leak on engine side. Repeat holding pressure test. This
time, close shut-off tap -A- to check whether leak actually is on
engine side.
nform
mercia

at
– If there is a leak on the engine side, carry out external check
om

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of the fuel pipes and high-pressure pump for leaks.

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c

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e

If no fault can be determined, check the injectors for leaks:

at

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– Remove spark plugs. Open shut-off valves -A- and -B-. Ac‐
for

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tuate fuel pump with final control diagnosis.

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Cop py
– Check through spark plug holes whether fuel has collected on
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the piston crown due to a leaking injector. p by
co Vo
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Prote AG.

8.3.5 Checking fuel delivery rate (engine co‐

des CAWA, CAWB, CBFA, CCTA,
CCTB, BZB, CGYA)
– Remove bench seat ⇒ General body repairs, interior; Rep. gr.
72 ; Removing and installing bench seat .

8. Repairing fuel supply system (Golf, Eos, Scirocco) 353

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Remove cover -1- with fuel pump control unit - J538- -2- from
fuel delivery unit.

– First check that the connector -arrow- is fitted securely by pull‐

ing the connector without pressing the catch. The connector
can cause a fault if it has not been fitted correctly.
– Now pull off connector.
– Check the contacts on the connector and on the fuel delivery
unit for damage.

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AG. Volkswagen AG d
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– Connect test instrument adapter/DSO (5-pin) - VASris5565-
ed to ara
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connector and fuel delivery unit. utho eo
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– Connect remote control - V.A.G 1348/3A- to adapter - VAS s

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5565- and to battery positive terminal clamp in the engine

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This step serves only to have the fuel pump running when the
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engine is stopped.

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Fuel supply line is pressurised. Wear protective goggles and

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Wrap a cloth around the connection before loosening hose
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connections. Then release pressure by carefully pulling hose

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off connection.
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– Pull off supply line (metal coupling) -arrow- and catch escaping
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fuel with a cloth.

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Cop py
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Press in securing ring to release the fuel lines.

354 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Connect pressure tester - VAS 6550- to fuel supply line with

adapter - VAS 6550/2- . Hold adapter - VAS 6550/1- in a
measuring container.
– Make sure that drain tap is closed and cut-off taps are open.

WARNING

Danger of spraying! Wear protective goggles and protective

clothing to avoid injury and contact with the skin. Hold container
in front of open connection of pressure tester.

– Operate remote control - V.A.G 1348/3A- . Then slowly close

shut-off tap -arrow- until a pressure of 4 bar is displayed on
pressure gauge. From this point on do not move position of
shut-off tap.
– Drain measuring container.

– The quantity delivered by the fuel pump depends on the bat‐

tery voltage. Therefore, also connect multimeter - V.A.G 1715-
to outputs -1 and 5- of test instrument/DSO adapter 5-pin -

cardiagn.com
VAS 5565- .
– Operate remote control for 60 seconds while measuring volt‐
age at fuel pump.

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– Compare quantity of fuel delivered with specification.orise nte
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*) Minimum delivery rate cm³/60 s ss a c

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Reading example:

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During the test a voltage of 10.5 volts is measured. This equates

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to a minimum delivery rate of approx. 1200 cm³/60 s
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spec
es, in part or in w

If specification is not obtained

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– Check fuel lines for possible restrictions (kinks) or blockages.
If no fault is found:
rrectness of i

– Remove cap from fuel filler neck and repeat check. If fuel de‐
l purpos

livery rate is now reached, check fuel tank breather.

If reading again does not match specification:
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– Check fuel filter (proceed as follows):

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WARNING
te

sd
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Fuel supply line is pressurised. Wear protective goggles and

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protective clothing to avoid injury and contact with the skin.

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Wrap a cloth around the connection before loosening hose C py
t. rig
connections. Then release pressure by carefully pulling hose
gh ht
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off connection.
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8. Repairing fuel supply system (Golf, Eos, Scirocco) 355

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Pull fuel supply line -arrow- off fuel filter.

AG. Volkswagen AG d
agen oes
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d b ara
rise nte
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spec
es, in part or in w

t to the co
– Connect pressure tester - VAS 6550- to fuel supply line with
adapter - VAS 6550/1- . Hold adapter - VAS 6550/2- in a
measuring container.

rrectness of i
– Make sure that drain tap is closed and cut-off taps are open.
l purpos

– Operate remote control - V.A.G 1348/3A- . Then slowly close

shut-off tap -arrow- until a pressure of 4 bar is displayed on

nform
ercia

pressure gauge. From this point on do not move position of

shut-off tap.
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tion in
– Drain measuring container.
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– Repeat delivery rate check.
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If the minimum delivery rate is now attained:
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– Renew fuel filter. Cop py
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– Remove fuel delivery unit and check filter strainer for soiling. Prote AG.

Only if still no fault has been detected:

– Renew fuel delivery unit.
If the fuel delivery rate has been attained but a fault is still sus‐
pected in the fuel supply system (e.g. intermittent failure of fuel
supply system):
– Measure current draw of fuel pump ⇒ page 358 .

8.3.6 Checking fuel delivery rate (engine co‐

des CCZA, CCZB, CDAA, CDAB)

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.

Checking fuel delivery rate in engine compartment:

– Connect vehicle diagnosis and service information system -
VAS 5052 B- to vehicle.
– Select Guided Functions in -VAS 5052 B- .
– Carry out identification of vehicle.
– Select Engine .
– Select Checking fuel delivery rate, quick test .

356 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Follow instructions on vehicle diagnosis and service informa‐

tion system - VAS 5052 B- .
Checking fuel delivery rate at flange:
• The guided function “Checking fuel delivery rate, quick test”
has been carried out ⇒ Vehicle diagnostic tester
• The remote control - V.A.G 1348/3A- and test instrument
adapter/DSO (5-pin) - VAS 5565- have been connected to the
fuel delivery unit.
• Battery charger connected
• Filling level in fuel tank above reserve
Test sequence
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The fuel line is under pressure. ss

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Fuel poses danger of injury to eyes and skin.

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Wear protective goggles and protective clothing to avoid injury
rm

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and contact with the skin. Wrap a cloth around the connection

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before loosening hose connections. Then reduce pressure by

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carefully opening the connection.
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es, in part or in w

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– Pull fuel supply line -arrow- off fuel filter.

rrectness of i
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tion in
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te o

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iva

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fo

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– Connect pressure tester - VAS 6550- to fuel supply line with
Co
op py
adapter - VAS 6550/1- . Hold adapter - VAS 6550/2- in a
t. C rig
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measuring container. p by
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– Make sure that drain tap is closed and cut-off taps are open. Prote AG.

– Operate remote control - V.A.G 1348/3A- . Then slowly close

shut-off tap -arrow- until a pressure of 4 bar is displayed on
pressure gauge. From this point on do not move position of
shut-off tap.
– Drain measuring container.

8. Repairing fuel supply system (Golf, Eos, Scirocco) 357

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– The quantity delivered by the fuel pump depends on the bat‐

tery voltage. Therefore, connect multimeter - V.A.G 1715- to
wires -1- and -5- of adapter - VAS 5565- in addition.
– Operate remote control for 60 seconds while measuring volt‐
age at fuel pump.

– Compare quantity of fuel delivered with specification.

*) Minimum delivery rate cm³/60 s
**) Voltage at fuel pump with engine not running and pump run‐
ning.
Reading example:
During the test a voltage of 10.5 volts is measured. This equates
gen AG
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to a minimum delivery rate of approx. 1200 cm³/60Vsolkswa not
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If specification is not obtained rise nte
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– Remove cap from fuel filler neck andssrepeat check. If fuel de‐ au ra
c
livery rate is now reached, check fuel tank breather.

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If reading again does not match specification:
itte

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– Remove fuel delivery unit and check filter strainer for soiling.

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– If no fault is found here either, renew flange with fuel filter.

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hole

spec
– Repeat check.
es, in part or in w

t to the co
If reading again does not match specification:
– Fuel pump defective, renew fuel delivery unit ⇒ page 320 .

rrectness of i
If fuel delivery rate has been attained, but nevertheless you sus‐
pect a fuel supply system fault (e.g. intermittent failure of fuel
l purpos

supply system): Check fuel pressure with the engine running

⇒ page 330 .
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orm

8.3.7 Checking current consumption

m

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om

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or c

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

thi
e

72 ; Removing and installing bench seat .

t

sd
iva

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r
rp

cu

– Remove cover -1- with fuel pump control unit - J538- -2- from
o

m
f

en
ng

fuel delivery unit.

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

358 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– First check that the connector -arrow- is fitted securely by pull‐

ing the connector without pressing the catch. The connector
can cause a fault if it has not been fitted correctly.
– Now pull off connector.
– Check the contacts on the connector and on the fuel delivery
unit for damage.

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byV ua
d ran
ir se tee
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– Connect test instrument adapter/DSO
auth (5-pin) - VAS 5565- to or
ac
connector and fuel deliveryssunit.

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pt
– Connect pick-up clamp -A- to red terminal with lettering “pick-
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• Specification: max. 9 amps

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♦ The starting current for the fuel pump can be briefly above
specifications when starting the engine.

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♦ If the fault in the fuel system is not always evident, the check

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8. Repairing fuel supply system (Golf, Eos, Scirocco) 359

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♦ Fuel hoses on the engine must only be secured with spring-

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type clips which conform to the production standard.

spec
urposes, in part or in wh

♦ Hose clip pliers - VAS 6362- or hose clip pliers - V.A.G 1921-

t to the co
are recommended for installation of spring-type clips.

rrectne
Safety precautions when working on fuel supply system
⇒ page 272 .

ss
Comply with rules for cleanliness ⇒ page 274 .

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Removing and installing fuel delivery unit ⇒ page 360 .

form
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Removing and installing fuel gauge sender - G- ⇒ page 363 .

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Removing and installing suction jet pump ⇒ page 364 .
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Removing and installing fuel gauge sender 2 - G169-

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⇒ page 366 .

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9.1 Removing and installing fuel delivery unit

360 Rep. gr.20 - Fuel supply system

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e d
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Special tools and workshop
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♦ Assembly tool - T10118-

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♦ Torque wrench - V.A.G

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1332-

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♦ Fuel extraction unit - VAS

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5190-

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Removing:

Caution

Condition:
• The fuel tank must be only 1/2 full or less. This ensures
that the fill level is below the flange of the fuel delivery unit.

Note

♦ When replacing fuel delivery unit, check fuel tank for heavy
soiling and clean if necessary.
♦ If necessary, drain fuel tank using fuel extractor - VAS 5190- .
♦ Note safety precautions before beginning work ⇒ page 272 .
♦ Observe rules for cleanliness ⇒ page 274 .

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

72 ; Removing and installing bench seat .

9. Repairing fuel supply (Tiguan) 361

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Remove cover from fuel delivery unit.

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– Check the contacts on the connector and on the fuel delivery
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unit for damage.
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– Release connector -arrow- on fuel pump control unit - J538-
using assembly tool - T10118- and pull it off.

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WARNING

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The fuel line is under pressure.

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and contact with the skin. Wrap a cloth around the connection
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– Pull off supply line -2- and catch escaping fuel with a cloth.
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– Open locking ring using key - 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.

– Slightly raise fuel delivery unit and remove seal out from aper‐
ture in fuel tank.

362 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Release fuel hoses on delivery unit -arrows- and pull delivery

unit out of fuel tank.

Note

If delivery unit is to be renewed, drain old delivery unit before dis‐

posal.

Installing

– Reconnect fuel hoses -arrows-. Ensure that fuel hoses engage

audibly and check to ensure firm seating by pulling!
– Further installation of the fuel delivery unit is carried out in re‐
verse order of removal.

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♦ Fuel hoses are allocated to respective unions.
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♦ When inserting the fuel delivery unit, ensure that the fuel

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gauge sender - G- is not bent.
♦ Insert seal for fuel delivery unit dry into opening of fuel tank.

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♦ Moisten seal with fuel only when installing fuel delivery unit.
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♦ Note installation position of flange for fuel delivery unit: tab

-1- must point in direction of travel. The fuel delivery unit flange

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can only be installed in this position.

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9.2 Removing and installing fuel gauge

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– Remove fuel delivery unit ⇒ page 360 .

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♦ Welding wire (2 mm thick)
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9. Repairing fuel supply (Tiguan) 363

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Bend an 80 mm long welding wire as shown.

Dimension -a- = 10 mm
Dimension -b-: 70 mm
Removing
– Release connector of wiring for fuel gauge sender and dis‐
connect it.

– Press welding wire -1- in direction of -arrow- into recess be‐

neath sender.
– At the same time, push fuel gauge sender -2- from guides in
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– Reconnect connector and check that it has engaged correctly.

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– Install fuel delivery unit ⇒ page 360 .
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9.3 Removing and installing suction-jet

pump, fuel filter and pressure limitation
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valve
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Special tools and workshop equipment required

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♦ Special wrench - T10202-

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364 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

♦ Torque wrench (40 to 200 Nm) - V.A.G 1332-

Note

♦ On vehicles with four-wheel drive, fuel must be pumped from

the area of fuel gauge sender 2 - G169- to the fuel pump unit
due to the shape of the fuel tank. To do so, a suction-jet pump
pumps fuel from left chamber to right chamber of fuel tank.

cardiagn.com
♦ The fuel delivery unit must first be removed to remove the
suction-jet pump.
♦ The left flange consists of suction-jet pump, fuel filter, pressure
limitation valve and fuel gauge sender 2 - G169- Only fuel
gauge sender 2 - G169- can be renewed separately.
♦ Checking fuel gauge sender 2 - G169- is only necessary when
the engine stops due to lack of fuel, even though the fuel
gauge shows that the tank is still 1/4 full. agen
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– Remove bench seat ⇒ General body repairs, interior;
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72 ; Removing and installing bench seat .

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– Remove fuel delivery unit ⇒ page 360 .
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– Remove left cover (as seen facing direction of normal travel)

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from fuel gauge sender 2 - G169- .

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hole

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

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9. Repairing fuel supply (Tiguan) 365

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Open locking ring using key - T10202- .

– Slightly raise flange and remove seal out from opening in fuel
tank.
– Pull flange together with fuel gauge sender 2 - G169- out of
fuel tank.
– Check fuel lines for kinks and damage.
– Additionally check suction-jet pump and fuel tank for possible
soiling.
Installing

Caution

When installing do not bend fuel gauge sender 2 - G169- float

arm.

– Install flange together with fuel gauge sender 2 - G169- in fuel

tank. The lug on the flange points in direction of travel.
– Place fuel lines in right chamber of fuel tank ensuring they are

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– Fit new seal for flange in fuel tank opening (seal should be ed by ara
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– Note installation position of fuel gauge sender 2 - G169-
ss

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⇒ page 300
nl

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– Check correct position of seal.
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– Tighten locking ring using wrench - T10202- . Specified torque:

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hole

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– Reconnect connector -1- and check it is secured properly by

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pulling.
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– Install fuel delivery unit ⇒ page 360 .

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Further assembly is performed in the reverse order of removal.
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9.4 Removing and installing fuel gauge

sender 2 - G169-
– Removing and installing suction-jet pump (Tiguan)
⇒ page 364 .

366 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

Special tools and workshop equipment required

♦ Welding wire (2 mm thick)
– Bend an 80 mm long welding wire as shown.
Dimension -a- = 10 mm
Dimension -b-: 70 mm
Removing
– Release connectors for lines for fuel gauge sender 2 - G169-
-2- and pull off.

– Press welding wire -1- inadirection

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Installing

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– Insert fuel gauge sender 2 - G169- into guides and press down

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until it engages.
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– Reconnect connector and check that it has engaged correctly.

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– Install suction-jet pump ⇒ page 364 . spec

es, in part or in w

t to the co
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nform
mercia

9.5 Removing and installing fuel pump con‐

a
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tion in

trol unit - J538-

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The fuel pump control unit - J538- is installed on the fuel tank.
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Special tools and workshop equipment required
agen
Prote AG.

♦ Commercially available flat-bladed screwdriver (blade width

120 mm)
Fuel pump control unit - J538- fitting location
1 - Bracket for fuel pump control unit - J538-
2 - Fuel pump control unit - J538-
3 - Connector
Removing
– Remove right (in direction of travel) cover from fuel delivery
unit.

9. Repairing fuel supply (Tiguan) 367

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– First ensure that 5-pin wiring connection -1- is secure by pull‐

ing the connector without pressing the catch. The connector
can cause a fault if it has not been fitted correctly.
– Now pull off connectors -1-.
– Check the contacts on the connector and on the fuel delivery
unit for damage.

– Slide screwdriver -2- into bracket recess -1- directly above

plug.
– Swivel screwdriver in direction of -arrow-.

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– Press screwdriver down in direction of -arrow-. Volksand
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unit out of bracket at plug at same wa gen AG
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– First check that the connector
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cause a fault if it has
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– Pull connector off control unit.

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– Reconnect connector -3- to control unit -2- and check engage‐

ment (pull back).
rrectness of i

– Slide control unit -2- into bracket -1- until it engages.

l purpos

Further installation is carried out in the reverse sequence of re‐

moval.
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Note
AG.

When replacing fuel delivery unit, check fuel tank for heavy soiling
and clean if necessary.

368 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

Special tools and workshop

equipment required
♦ Pressure gauge - VAS
6550-
♦ Remote control - V.A.G AG. Volkswagen AG d
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♦ Test instrument adapter/ rised
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DSO (5-pin) - VAS 5565- aut
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♦ Multimeter - V.A.G 1715-

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♦ Special wrench - T10202-
itte

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♦ Measuring container, ca‐

ility
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pacity: 3 litres

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⇒ “9.6.1 Checking function and voltage supply”, page 369

⇒ “9.6.2 Checking fuel pressure”, page 371
⇒ “9.6.3 Checking fuel pressure when the engine is running and
vehicle is in gear (engine codes CCZA, CCZB, CCZC, CCZD)”,
page 372
⇒ “9.6.4 Checking holding pressure”, page 375
⇒ “9.6.5 Checking fuel delivery rate (engine codes CAWA,
CAWB, CCTA, CCTB)”, page 376
⇒ “9.6.6 Checking fuel delivery rate (engine codes CCZA, CCZB,
CCZC, CCZD)”, page 378
⇒ “9.6.7 Checking current consumption”, page 380

9.6.1 Checking function and voltage supply

• Battery voltage at least 12 V
• Fuse for fuel pump on fuse holder OK ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
• Fuel pump control unit - J538- OK.

9. Repairing fuel supply (Tiguan) 369

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

Test sequence

Note

♦ Function of fuel pump is checked using final control diagnosis.

♦ 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.

– Connect vehicle diagnostic tester as follows:

– Push diagnosis cable connector onto diagnosis connection in
driver footwell. swa
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– Switch ignitionedon.
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– Press right arrow button ► on display up to final control diag‐
erm

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The fuel pump must now run slowly up to maximum speed.

h re
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spec
es, in part or in w

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Note

The fuel pump runs very quietly.

rrectness of i

– Switch off ignition.

l purpos

If fuel pump does not run:

nf
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– Remove bench seat ⇒ General body repairs, interior; Rep. gr.

rm

72 ; Removing and installing bench seat .

m

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– Remove right (in direction of travel) cover from fuel delivery

or

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unit.
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Note
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For vehicles with auxiliary heater the metering pump - V54- con‐
ht
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nector must be separated additionally.
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– First ensure that 5-pin wiring connection -1- is secure by pull‐

ing the connector without pressing the catch. If connector was
not inserted correctly, repeat functional check of fuel pump.
– Now pull off connectors -1-.
– Check the contacts on the connector and on the fuel delivery
unit for damage.

370 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

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

connector and fuel delivery unit.
– Connect multimeter - V.A.G 1715- to contacts -1- and -5- of
adapters - VAS 5565- .
– Actuate fuel pump with final control diagnosis.
• The voltage must rise to about 9 V during the final control di‐
agnosis.
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:
– Remove fuel delivery unit ⇒ page 360 .
– Check that electrical wires between flange and fuel pump are
connected.
If no open circuit can be found:
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– Fuel pump defective,
Vol
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renew fuel delivery unitno⇒
t gupage 360 .

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9.6.2 Checking fuel pressure
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Test conditions:
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• Function of fuel pump has been checked ⇒ page 369 .

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Test sequence
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♦ The fuel pressure must be checked by means of the final con‐

trol diagnosis. If the fuel pressure is measured at idling speed,
rrectness of i

it may deviate from the specification.

♦ If the final control diagnosis is to be carried out several times
l purpos

in succession, it may be necessary to start the engine briefly

before repeating the final control diagnosis.
nform
mercia

at
om

io

WARNING
n
c

in t
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te

Fuel supply line is pressurised. Wear protective goggles and

a

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protective clothing to avoid injury and contact with the skin.

p

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Wrap a cloth around the connection before loosening hose

f

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ng

t.
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connections. Then release pressure by carefully pulling hose
Co
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off connection.
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pyri by
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cted agen
Prote AG.
– Pull off supply line (metal coupling) -2- and catch escaping fuel
with a cloth.

9. Repairing fuel supply (Tiguan) 371

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Connect pressure tester - VAS 6550- to fuel supply line with

adapter - VAS 6550/1- and -VAS 6550/2- .
– Make sure that drain tap is closed and cut-off taps are open.
– Actuate fuel pump with final control diagnosis to build up fuel
pressure.
– Read fuel pressure on pressure gauge.
• Specification: 4.0 to 7.0 bar
If fuel pressure is OK, check holding pressure ⇒ page 375 .
If specification is not obtained
– Renew left flange with pressure limiting valve, suction jet pump
and fuel filter.

Note

Pressure limiting valve and fuel filter are integrated into fuel gauge
sender 2 - G169- with suction-jet pump and cannot be renewed
individually.

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– Repeat check. agen
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oes
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If reading again does not match specification: ed by ara
nte
ris
o eo
– Fuel pump defective, renew fuel delivery unit ⇒apage
ut
h
360 . ra
ss c

ce
le
un

9.6.3 Checking fuel pressure when the engine

pt
an
d
itte

y li
is running and vehicle is in gear (engine
erm

ab
ility
codes CCZA, CCZB, CCZC, CCZD)
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

Note

t to the co
♦ If a complaint is made about the vehicle's performance, the
reason may be that the fuel pressure is too low. Faults in the

rrectne
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 ss o
cial p

f i
section is read from the engine control unit. The lowest fuel
nform

pressure is measured by the pressure tester - VAS 6550- and

mer

reported to the vehicle diagnosis and service information sys‐

atio
m

tem - VAS 5052 B- .

o

n
c

i
or

n thi
e

♦ This test can be part of “Guided Fault Finding” if an entry has

t

sd
va

been made in the event memory. However, it can also be star‐

i

o
pr

cum
r

ted in the vehicle diagnosis and service information system -

fo

en
ng

VAS 5052 B- by means of “Functions and component

t.
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selection”. C py
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Special tools and workshop equipment required
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Prote AG.
♦ Pressure gauge - VAS 6550-
♦ Hose adapters - VAS 6550/1- and -VAS 6550/2-
♦ Vehicle diagnosis and service information system - VAS 5052
B-
♦ Connector cable - VAS 5051/66-
– Remove bench seat ⇒ General body repairs, interior; Rep. gr.
72 ; Removing and installing bench seat .

372 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Remove right (in direction of travel) cover from fuel delivery

unit.

Note

For vehicles with auxiliary heater the metering pump - V54- con‐
nector must be separated additionally.

– First ensure that 5-pin wiring connection -1- is secure by pull‐

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

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.

cardiagn.com
– Pull off supply line -2- and catch escaping fuel with a cloth.

AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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le
un

pt
an
d
itte

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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

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r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

9. Repairing fuel supply (Tiguan) 373

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Connect pressure tester - VAS 6550- to fuel supply line with

adapter - VAS 6550/2- and -VAS 6550/1- .
– Fit connector cable - VAS 5051/66- to pressure tester - VAS
6550- and to vehicle diagnosis and service information system
- VAS 5052 B- .
– Make sure that drain tap is closed and cut-off taps are open.
– Switch on pressure tester - VAS 6550- .
AG. Volkswagen
If the fuel pressure test is carried
ksw
agen out within “Guided
AG do
eFault
s no Find‐
y Vol of the diagnostic tester.
ing”, follow the instructions t gu
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ris t
If the fuel pressure
ut test is carried out without “Guided Fault Find‐
ho
ee
or
ing”, proceed sas
s follows:
a ac

ce
le

– Connect vehicle diagnosis and service information system -

un

pt
an
d

VAS 5052 B- to vehicle.

itte

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rm

ab
– Select Guided Fault Finding in -VAS 5052 B- .
pe

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ot

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– Carry out identification of vehicle.

h re
hole

spec
– Using the GoTo button, select the following menu options one
es, in part or in w

after the other:

t to the co

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♦ Function/component selection

rrectness of i
♦ Drive
l purpos

♦ Engine
♦ 24 Mixture preparation/injection
nform
ercia

♦ Mechanical components
m

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tio

♦ High-pressure pump
n in
r
te o

thi

– Follow instructions on vehicle diagnosis and service informa‐

s
iva

do

tion system - VAS 5052 B- .

r
rp

cum
fo

en
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t.
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op
WARNING C py
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Vo
Test instruments and measuring equipment must always be
o
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secured to the rear seat and operated by a second person from
Prote AG.
this location.

374 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

9.6.4 Checking holding pressure

Prerequisites for check
• Fuel pressure OK and pressure tester - VAS 6550- connected.
Check fuel pressure ⇒ page 348 .
Test sequence AG. Volkswagen AG d
agen oes
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– Actuate fuel pump with final control diagnosis to build up d bfuel
y Vo gu
ara
pressure. orise nte
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– Read fuel pressure on pressure gauge. ss a c

ce
le
• Specification: 4.0 to 7.0 bar

un

pt
an
d
itte

y li
– End self-diagnosis, and switch off ignition.

rm

ab
pe

ility
– Watch pressure drop on pressure gauge. Pressure must re‐
ot

wit
, is n
main above 3.0 bar for 10 minutes.

h re
hole

spec
If the pressure drops further:
es, in part or in w

t to the co
– Actuate fuel pump with final control diagnosis to build up fuel
pressure.

rrectness of i
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– After pressure has built up, close cut-off tap -B- of pressure
tester immediately. Lever is then at right angle to direction of
l purpos

flow.
If the pressure drops again (leak on fuel tank side):

nform
ercia

Leak must be sought on fuel tank side; proceed as follows:

m

a
com

tion in
– Check fuel line to flange for leaks.
r
te o

thi
If no fault is detected on »external« fuel lines, search for leak in

s
iva

do
r

fuel tank. Proceed as follows:

rp

cum
fo

en
g

– Open flanges on left and right. Ensure all hose connections

n

t.
yi Co
op
are fitted correctly and do not leak. C py
t. rig
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yri by
If no fault is found: cop Vo
by lksw
cted agen
Prote
– First renew left flange with pressure limiting valve and fuel fil‐
AG.

ter. Repeat pressure retention test. If leak is still present, non-

return valve in fuel pump leaks, renew fuel delivery unit.
If the pressure does not drop now (leak on engine side):

Note

Search for leak on engine side. Repeat holding pressure test. This
time, close shut-off tap -A- to check whether leak actually is on
engine side.

– If there is a leak on the engine side, carry out external check

of the 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
the piston crown due to a leaking injector.

9. Repairing fuel supply (Tiguan) 375

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

9.6.5 Checking fuel delivery rate (engine co‐

des CAWA, CAWB, CCTA, CCTB)
Test conditions
• Voltage supply OK.
• 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. en AG. V
olkswagen AG
wag does
olks no
– Remove bench seat ⇒ byGeneral body repairs, interior; Rep.
V t gu gr.
ara
ed
72 ; Removing and
or installing bench seat .
is nte
e h
ut or
– Remove rightss(in
a
direction of travel) cover from fuel delivery ac
unit.

ce
e
nl

pt
du

an
itte

y li
erm

ab
Note

ility
ot p

wit
, is n

For vehicles with auxiliary heater the metering pump - V54- con‐

h re
hole

nector must be separated additionally.

spec
es, in part or in w

t to the co

cardiagn.com
– First ensure that 5-pin wiring connection -1- is secure by pull‐
ing the connector without pressing the catch. The connector
can cause a fault if it has not been fitted correctly.

rrectness of i
– Now pull off connectors -1-.
l purpos

– Check the contacts on the connector and on the fuel delivery

unit for damage.
nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

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r
rp

cu
o

m
f

en
ng

t.
yi
– Connect test instrument adapter/DSO (5-pin) - VAS 5565- to
Co
op py
connector and fuel delivery unit.
t. C rig
gh ht
pyri by
Vo
o
– Connect remote control - V.A.G 1348/3A- to test instrument
c by lksw
cted agen
adapter/DSO (5-pin) - VAS 5565- and to battery positive (+). Prote AG.

376 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Pull off supply line (metal coupling) -2- and catch escaping fuel
with a cloth.

Note

Press in securing ring to release the fuel lines.

n AG. Volkswagen AG do
lkswage es n
o ot g
yV ua
– Connect pressure ir se tester - VAS 6550- to fuel supply line with
d b ran
t
adapter - VASuth6550/2- . Hold adapter - VAS 6550/1- in a ee or
o
measuring scontainer.
s a ac

ce
le

– Make sure that drain tap is closed and cut-off taps are open.
un

pt
an
d
itte

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erm

ab
WARNING

ility
ot p

wit
is n

Danger of spray when shut-off tap is opened. Wear eye pro‐

h re

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ole,

tection and protective clothing to avoid injuries and skin con‐

spec
urposes, in part or in wh

tact. Hold container in front of open connection of pressure

t to the co
tester.

rrectne
– Operate remote control - V.A.G 1348/3A- . Then slowly close
shut-off tap -arrow- until a pressure of 4 bar is displayed on
pressure gauge. From this point on do not move position of ss o
shut-off tap.
cial p

f inform

– Drain measuring container.

mer

atio
om

– The quantity delivered by the fuel pump depends on the bat‐

c

i
or

tery voltage. Therefore, connect multimeter - V.A.G 1715- to

thi
te

sd
a

wires -1- and -5- of adapter - VAS 5565- in addition.

iv

o
pr

cum
r
fo

– Operate remote control for 60 seconds while measuring volt‐

en
ng

t.
age at fuel pump.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

9. Repairing fuel supply (Tiguan) 377

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Compare quantity of fuel delivered with specification.

*) Minimum delivery rate cm³/60 s
**) Voltage at fuel pump with engine 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 cm³/60 s
If specification is not obtained
– Check fuel lines for possible restrictions (kinks) or blockages.
AG. Volkswagen AG d
agen oes
If no fault is found: o lksw not
y V gu
d b ara
e
– Remove cap from fuel filler neck and repeathocheck.
ris If fuel de‐ nte
eo
livery rate is now reached, check fuel tank
s a breather.
ut ra
c
s
If reading again does not match specification:

ce
le
un

pt
an
d
itte

– Open flanges on left and right. Ensure all hose connections

y li
rm

ab
are fitted correctly and do not leak. Check sieve in fuel delivery
pe

ility
unit and fuel tank for coarse soiling.
ot

wit
, is n

cardiagn.com
h re
If no fault is found:
hole

spec
– First renew left flange with pressure limiting valve and fuel fil‐
es, in part or in w

t to the co
ter. Repeat delivery rate check. If fuel delivery is still insuffi‐
cient, fuel pump defective, renew fuel delivery unit.
If the fuel delivery rate has been attained but a fault is still sus‐

rrectness of i
pected in the fuel supply system (e.g. intermittent failure of fuel
supply system):
l purpos

– Measure current draw of fuel pump ⇒ page 380 .

nform
ercia

9.6.6 Checking fuel delivery rate (engine co‐

m

a
com

tio
des CCZA, CCZB, CCZC, CCZD)

n in
r
te o

thi
s
iva

do
r
rp

cum

Note
fo

en
ng

t.
yi Co
op
The fuel delivery rate must first be checked in the engine com‐
C py
t. rig
gh
partment with the help of the function “Checking fuel delivery rate,
ht
pyri by
Vo
o
quick test”. If the minimum delivery rate is not achieved, a 2nd
c by lksw
cted agen
measurement must be carried out at the flange of the fuel delivery Prote AG.

unit.

Checking fuel delivery rate in engine compartment:

– Connect vehicle diagnosis and service information system -
VAS 5052 B- to vehicle.
– Select Guided Functions in -VAS 5052 B- .
– Carry out identification of vehicle.
– Select Engine .
– Select Checking fuel delivery rate, quick test .
– Follow instructions on vehicle diagnosis and service informa‐
tion system - VAS 5052 B- .
Checking fuel delivery rate at flange:
• The guided function “Checking fuel delivery rate, quick test”
has been carried out ⇒ Vehicle diagnostic tester

378 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

• The remote control - V.A.G 1348/3A- and test instrument

adapter/DSO (5-pin) - VAS 5565- have been connected to the
fuel delivery unit.
• Battery charger connected AG. Volkswagen AG d
agen oes
olksw not
yV gu
• Filling level in fuel tank above reserve ed b ara
nte
ris
ho eo
Test sequence aut ra
c
ss

ce
le
un

pt
WARNING

an
d
itte

y li
rm

ab
The fuel line is under pressure.

pe

ility
ot

wit
, is n
Fuel poses danger of injury to eyes and skin.

h re
hole

spec
Wear protective goggles and protective clothing to avoid injury
es, in part or in w
and contact with the skin. Wrap a cloth around the connection

t to the co
before loosening hose connections. Then reduce pressure by
carefully opening the connection.

rrectness of i
– Pull supply line -2- off right flange and catch escaping fuel with
l purpos

a cloth.

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mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Connect pressure tester - VAS 6550- to flange with adapter -
VAS 6550/2- . Hold adapter - VAS 6550/1- in a measuring
container.
– Make sure that drain tap is closed and cut-off taps are open.
– Press the remote control - V.A.G 1348/3A- and slowly close
shut-off tap -arrow- until a pressure of 4 bar is displayed on
pressure gauge. From this point on do not move position of
shut-off tap.
– Drain measuring container.

– The quantity delivered by the fuel pump depends on the bat‐

tery voltage. Therefore, connect multimeter - V.A.G 1715- to
wires -1- and -5- of adapter - VAS 5565- in addition.
– Operate remote control for 60 seconds while measuring volt‐
age at fuel pump.

9. Repairing fuel supply (Tiguan) 379

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Compare quantity of fuel delivered with specification.

*) Minimum delivery rate cm³/60 s
**) Voltage at fuel pump with engine 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 cm³/60 s
If specification is not obtained
– Check fuel lines for possible restrictions (kinks) or blockages.
If no fault is found:
– Remove cap from fuel filler neck and repeat check. If fuel de‐
livery rate is now reached, check fuel tank breather.
If reading again does not match specification:
– Open flanges on left and right. Ensure all hose connections
are fitted correctly and do not leak. Check sieve in fuel delivery
unit and fuel tank for coarse soiling.

cardiagn.com
If no fault is found: agen
AG. Volkswagen AG d
oes
olksw not
V
– First renew left flange with pressure limiting valve d band fuel fil‐
y gu
ara
ter. Repeat delivery rate check. If fuel delivery rise still insuffi‐
is nte
ho eo
cient, fuel pump defective, renew fuel delivery
s aut
unit. ra
c
s
If fuel delivery rate has been attained, but nevertheless you sus‐

ce
e
nl

pt
du

pect a fuel supply system fault (e.g. intermittent failure of fuel

an
itte

y li
supply system): Check fuel pressure with the engine running
erm

ab
⇒ page 372 .

ility
ot p

wit
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h re
9.6.7 Checking current consumption
hole

spec
es, in part or in w

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

t to the co
72 ; Removing and installing bench seat .
– Remove right (in direction of travel) cover from fuel delivery

rrectness of i
unit.
l purpos

– First ensure that 5-pin wiring connection -1- is secure by pull‐

ing the connector without pressing the catch. The connector
can cause a fault if it has not been fitted correctly.
nf
ercia

or

– Now pull off connectors -1-.

m
m

atio
m

– Check the contacts on the connector and on the fuel delivery

o

n in
or c

unit for damage.

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

380 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engineen(1.8 and
AG. V 2.0
olkswagelnengine,
AG chain drive) - Edition 02.2017
ag does
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y Vol gu
– Connect test instrument adapter/DSO d b (5-pin) - VAS 5565- to ara
ise nte
connector and fuel delivery unit.
thor eo
au ra
c
– Connect pick-up clamp -A- sto red terminal with lettering “pick-
s

ce
le
up clamp” for test instrument adapter/DSO (5-pin) - VAS

un

pt
an
5565- .

d
itte

y li
rm

ab
– Start engine and run at idling speed.
pe

ility
ot

wit
– Measure current draw of fuel pump.
, is n

h re
hole

• Specification: max. 16 amps

spec
es, in part or in w

t to the co
Note

rrectness of i
♦ The starting current for the fuel pump can be briefly above
specifications when starting the engine.
l purpos

♦ If the fuel system malfunction is intermittent, you can perform

the check during a road test, but a 2nd person is necessary.

nform
mercia

a
com

If the current draw is exceeded:

tion in
r
te o

– Fuel pump defective, renew fuel delivery unit ⇒ page 360 .

thi

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s
iva

do
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rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
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co lksw
by
cted agen
Prote AG.

9. Repairing fuel supply (Tiguan) 381

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

10 Electronic power control (EPC)

Assembly overview - accelerator module ⇒ page 382 .
Removing and installing accelerator module ⇒ page 382 .

10.1 Assembly overview - accelerator module

1 - Connector
❑ Black, 6-pin.
2 - Accelerator position sender
- G79- with accelerator posi‐
tion sender 2 - G185-
❑ Not adjustable.
❑ The accelerator position
sender passes the posi‐
tion of the accelerator
on to the engine control
unit. agen
AG. Volkswagen AG d
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❑ -A- openings for release Vo gu

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by ara
d
tool . orise nte
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❑ Removing and installing s a u ra
c
⇒ page 382 s

ce
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nl

pt
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3 - 10 Nm

an
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4 - Cap

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spec
es, in part or in w

t to the co
rrectness of i
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ercia

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m

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or c

thi
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Cop py
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10.2 Removing and installing accelerator
p by
co Vo
by lksw
cted
pedal module
agen
Prote AG.

Special tools and workshop equipment required

382 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

♦ For left-hand drive vehicles: release tool - T10238-

Or
♦ For right-hand drive vehicles: release tool - T10240-
Removing

cardiagn.com
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
s c
– Remove steering column cover -arrows-. s

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness

– Prise out cap -3- using a screwdriver.

o
cial p

f in

– Remove bolts -2-.

form
mer

atio

– Release connector -1- -arrow- and pull off accelerator module.

om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

10. Electronic power control (EPC) 383

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Push release tool - T10238- (for right-hand drive vehicles re‐

lease tool - T10240- ) into intended holes as shown to stop
and remove accelerator module.

Note

In the Tiguan, raise the release tool slightly and then insert it at a
slight angle.

Installing

– Reconnect connector -1- to accelerator module -4-. Lock con‐ AG. Volkswagen AG d
agen
nector -arrow-. Volksw
oes
not
by gu
d ara
– Press accelerator module onto securing pins -5-. orise nte
e
th or
– Insert centring pin -6- into hole in underbody. s au ac
s

ce
le

– Secure accelerator module with bolt -2- and install cap -3-.
un

pt
an
d
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ab

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pe

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es, in part or in w

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– Install steering column trim.

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tion in
Specified torque:
r
te o

thi
s
iva

Component Nm

do
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rp

cum
fo

Accelerator module to body 10 en

ng

t.
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by
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Prote AG.

384 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

11 Activated charcoal filter system (Pas‐

sat, CC, Tiguan)
Assembly overview - activated charcoal filter system (engine co‐
des BZB, CAWA, CAWB, CGYA, CCZA, CCZB, CCZC, CCZD,
CDAA, CDAB) ⇒ page 385 .
Assembly overview - activated charcoal filter system (engine co‐
des CBFA, CCTA, CCTB) ⇒ page 386 .
Checking fuel tank breather (engine codes BZB, CAWA, CAWB,
CGYA, CCZA, CCZB, CCZC, CCZD, CDAA, CDAB)
⇒ page 388 .
Check fuel system for leaks CBFA, CCTA, CCTB ⇒ page 390 .

Note

♦ Hose connections are secured with either spring-type or

clamp-type clips.
♦ Spring-type clip pliers - VAS 6340- or space saving hose clip

cardiagn.com
pliers - VAS 6362- are recommended for installing and remov‐
ing spring-type clips.

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
AG. Volkswagen AG d
agen oes
Fuel supply black Volksw not
gu
by ara
Fuel return blue rise
d
nte
ho eo
Breather white, beige s aut ra
c
s
Vacuum green

ce
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nl

pt
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an
itte

11.1 Assembly overview - activated charcoal filter system (engine codes BZB,

y li
erm

ab
CAWA, CAWB, CGYA, CCZA, CCZB, CCZC, CCZD, CDAA, CDAB)

ility
ot p

wit
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h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
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orm
m

atio
om

n in
or c

thi
te

sd
iva

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rp

cu
o

m
f

en
ng

t.
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Cop py
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Vo
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11. Activated charcoal filter system (Passat, CC, Tiguan) 385

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

1 - Activated charcoal filter

❑ Location: in rear right
wheel housing.
❑ To remove, unscrew se‐
curing bolts and pull ac‐
tivated charcoal filter
downwards out of re‐
tainer.
AG. Volkswagen AG d
agen
2 - Pressure retention valve olksw
oes
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❑ To remove, grasp se‐ ut
ho eo
ra
curing ring (grey) and ss a c
pull off upwards.

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❑ Ensure firm seating.
d
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3 - From fuel tank
pe

ility
ot

wit
4 - Breather hose
, is n

h re
hole

❑ To activated charcoal fil‐

spec
ter solenoid valve 1 -
es, in part or in w

N80-

t to the co
⇒ Item 6 (page 386)

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❑ Clipped onto fuel tank.

rrectness of i
❑ Ensure firm seating.
l purpos

5 - Breather hose
❑ From activated charcoal

nform
ercia

filter
⇒ Item 1 (page 386)
m

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tio
❑ Ensure firm seating.

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6 - Activated charcoal filter sol‐ s
iva

do
enoid valve 1 - N80-
r
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fo

❑ Valve closed with igni‐

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ng

t.
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tion switched off
Co
Cop py
.
❑ When engine is warm,
ht rig
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valve will be activated copy Vo
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7 - Connection hose
❑ To intake manifold
❑ Ensure firm seating.
8 - 10 Nm

11.2 Assembly overview - activated charcoal

filter system (engine codes CBFA,
CCTA, CCTB)

Note

On some vehicles an additional filter is installed on the activated

charcoal filter system

Assembly overview - activated charcoal filter system

⇒ page 387
Assembly overview - activated charcoal filter system (vehicles
with additional filter) ⇒ page 388 .

386 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

11.2.1 Assembly overview - activated charcoal filter system

1 - Securing bolts
2 - Fuel system diagnostic
pump - V144-
3 - Vacuum line
4 - Clamp AG. Volkswagen AG d
agen oes
olksw not
5 - Connection hose d by V gu
ara
ise nte
❑ Activated thor charcoal fil‐ eo
ter s/s afuel system diag‐
u ra
c
nostic pump - V144-

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6 - Vacuum hose
itte

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7 - Connection hose

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❑ Fuel system diagnostic

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pump - V144- / air filter.
hole

spec
8 - Air filter
es, in part or in w

t to the co

cardiagn.com
9 - 10 Nm
10 - Activated charcoal filter

rrectness of i
❑ Location: in rear right
wheel housing.
l purpos

❑ To remove, unscrew se‐

curing bolts and pull ac‐
nform
ercia

tivated charcoal filter

m

downwards out of re‐

at
om

tainer.
on
c

in t
or

11 - Breather hose
his
ate

do
riv

❑ To activated charcoal fil‐

p

cum
or

ter solenoid valve 1 -

f

en
ng

t.
N80-
yi Co
Cop py
❑ Clipped onto fuel tank.
t. rig
gh ht
pyri by
Vo
o
12 - Breather hose
c by lksw
cted agen
Prote AG.
❑ From fuel tank

11. Activated charcoal filter system (Passat, CC, Tiguan) 387

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

11.2.2 Assembly overview - activated charcoal filter system (vehicles with addi‐
tional filter)

1 - Fuel system diagnostic

pump - V144-
AG. Volkswagen AG d
2 - Vacuum line agen oes
olksw not
V gu
by ara
3 - Vacuum hose rised
nte
ho eo
ut
4 - Connection hose ss a ra
c

ce
le
5 - Clamp

un

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6 - Breather hose
rm

ab
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❑ From fuel tank
ot

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7 - Clip

h re
hole

spec
8 - Connection hose
es, in part or in w

t to the co
❑ Fuel system diagnostic
pump - V144- / air filter.
9 - Securing bolt

cardiagn.com
rrectness of i
10 - Air filter
l purpos

11 - Additional filter

nform
ercia

12 - 10 Nm
m

a
13 - Breather hose
com

tion in
❑ To activated charcoal fil‐
r
te o

thi
ter solenoid valve 1 -

s
iva

do
N80-
r
rp

cum
fo

❑ Clipped onto fuel tank.

en
ng

t.
yi Co
op
14 - Connection hose
C py
t. rig
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yri by
15 - Activated charcoal filter
op Vo
by c lksw
cted agen
❑ Location: in rear right Prote AG.
wheel housing.
❑ To remove, unscrew se‐
curing bolts and pull ac‐
tivated charcoal filter
downwards out of re‐
tainer.
16 - Securing bolts

11.3 Checking fuel tank breather (engine co‐

des BZB, CAWA, CAWB, CGYA, CCZA,
CCZB, CCZC, CCZD, CDAA, CDAB)
Special tools and workshop equipment required

388 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

♦ Hand operated vacuum pump - VAS 6213-

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

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un

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erm

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ility
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is n

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ole,

spec
urposes, in part or in wh

t to the co
Test sequence
– Pull off breather line -2-. To do this, press release button. (col‐

rrectne
our marking: white)

ss o
cial p

f inform
mer

cardiagn.com
atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
– Then connect hand vacuum pump - VAS 6213- as shown to yri
p by
o Vo
breather line. by c lksw
cted agen
Prote AG.

– Move slide ring -1- on hand vacuum pump - VAS 6213- to po‐
sition -A- for “vacuum”.
– Operate hand vacuum pump - VAS 6213- several times. There
must be no development of vacuum.

11. Activated charcoal filter system (Passat, CC, Tiguan) 389

 n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
ed ran
CC 2010 ➤ , Eos hor 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat
is tee 2006 ➤ , ...
t or
4-cyl. injection au engine (1.8 and 2.0 l engine, chain drive) - Edition ac 02.2017
ss

ce
e
nl
– Seal breather hole on activated charcoal filter -arrow- and op‐

pt
du

an
itte
erate vacuum pump several times again. Vacuum must build

y li
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ab
up.

ility
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wit
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es, in part or in w

t to the co
rrectness of i
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nf
ercia

11.4 Check fuel system for leaks (engine co‐

orm
des CBFA, CCTA, CCTB)
m

atio
om

n in
or c

Special tools and workshop equipment required

thi
te

sd
iva

♦ Fuel system tester (so-called smoke tester) - KLI 9210-

o
r
rp

cu
o

m
f

♦ Adapter hose - KLI 9210/55-1-

en
ng

t.
yi Co
op

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py
♦ Vehicle diagnostic tester t. C rig
gh ht
pyri by
♦ Hose clamps to 25 mm - 3094-
co Vo
by lksw
cted agen
Prote AG.

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 blue
Breather white, beige
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.

390 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Check on fuel system tester - KLI 9210- if 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-.
– Set valve -D- to “Hold”.
– Now pressure must be maintained for at least 2 minutes.
Check tester if pressure is not maintained.
Checking fuel system for leaks:

cardiagn.com
– Connect adapter hose - KLI 9210/55-1- to breather line -A-.
(colour marking: white)

n AG. Volkswagen AG do
swage es n
– Connect measuring hose -G- from by V fuel system tester - KLI
olk ot g
ua
9210- to adapter hose - KLIris9210/55-1-
ed . ran
tee
tho
or
– Set valve -D- to “Hold”.s au ac
s
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pe

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spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co

391
by lksw
cted agen
Prote 11. Activated charcoal filter system (Passat, CC, Tiguan)
AG.
 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– 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 “Checking tank ventilation system for

leaks”.
– Initiate 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 off ignition and perform a pressure retention test
⇒ page 392 . If no pressure drop can be detected: Check
vacuum supply of fuel system diagnostic pump - V144-
⇒ page 396 .
The minimum pressure was not reached and the available pres‐
sure drops immediately:

cardiagn.com
– Clamp off hose to activated charcoal filter solenoid
swa
gen Avalve
G. Volk1 -
swagen AG
does
N80- using a hose clip -arrow-. by Volk not
gu
d ara
se nte
– Repeat check. If the minimum pressure ho
ri is reached now, renew e
ut
activated charcoal filter solenoids avalve 1 - N80- .
or
ac
s

ce
e

If the minimum pressure was again not reached and the available
nl

pt
du

pressure drops immediately:

an
itte

y li
erm

ab
– Leak in fuel system: Perform “leak detection in fuel system”
ility
ot p

⇒ page 394 .
wit
, is n

Switch off ignition if the minimum pressure is reached. h re

hole

spec
The valve in the fuel system diagnostic pump - V144- closes and
es, in part or in w

t to the co

the pressure is retained.

– Observe pressure gauge:
rrectness of i

If the pressure does not drop at first, perform a pressure retention

test to localise any potential small leaks ⇒ page 392 .
l purpos

If the pressure drops, clamp off hose to activated charcoal filter

nform
ercia

solenoid valve 1 - N80- using a hose clip -arrow-.

m

at

– If the pressure does not drop again, renew activated charcoal

om

ion

filter solenoid valve 1 - N80- .

c

in t
or

his
te

If the pressure still drops, perform “leak detection in fuel system”

a

do
riv

⇒ page 394 .
p

cum
for

en
ng

Pressure retention test

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

392 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Set valve -D- to “Test”. Set the available pressure to 10 in. H2O
(25 mbar).
– Observe pressure gauge -C- and flow meter -E-. When the
throughput quantity decreases and the pressure increases to
10 in. H2O (25 mbar), the 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 the 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

cardiagn.com
leaks. To do this, clamp off hose to activated charcoal filter
solenoid valve 1 - N80- using a hose clip -arrow-.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
– Repeat pressure test by setting valve -D- again to “Test”.
ce
e
nl

pt
du

an

– Observe pressure gauge and flow meter. When the through‐

itte

y li

put quantity decreases and the pressure increases to 10 in.

erm

ab

H2O (25 mbar), the fuel system is filled.

ility
ot p

wit
, is n

– Once pressure has stabilised, set valve -D- to “Hold”.

h re
hole

spec

– If the pressure does not drop again, renew activated charcoal

es, in part or in w

filter solenoid valve 1 - N80- .

t to the co

If the pressure still drops, perform “leak detection in fuel system”

⇒ page 394 .
rrectness of i

After completing work, perform guided function “checking fuel

l purpos

tank ventilation system for leaks” using vehicle diagnostic tester .

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

11. Activated charcoal filter system (Passat, CC, Tiguan) 393

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

11.4.1 Leak detection in fuel system

Test specification: n AG. Volkswagen AG do
lkswage es n
o ot g
• Procedure for “checking fuel system ford bleaks”
yV has been com‐ ua
ran
pleted ⇒ page 390 . orise
tee
th or
u
• Fuel system tester - KLI 9210- sis
s connected to vehicle via
a ac
adapter hose - KLI 9210/55-1- .

ce
le
un

pt
an
d
– Connect fuel system tester - KLI 9210- to vehicle battery.
itte

y li
rm

ab
pe

– Remove rear right wheel housing liner.

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
– Clamp off hose between fuel system diagnostic pump - V144-

rrectness of i
and air filter -arrow-.
l purpos

nform
ercia

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m

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

394 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Set valve -D- to “Test”.

– Observe pressure gauge -C- and flow meter -E-. When the
throughput quantity decreases and the pressure increases to
10 in. H2O (25 mbar), the fuel system is filled.
– Once pressure has stabilised, set valve -D- to “Hold”.
• After 5 minutes the 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, set valve -D- again to “Test” for
this.
– While fuel system is being filled, press button -I- for smoke
generator for approx. one minute.
The fuel system is now pressurised and filled with smoke.
– Check whether smoke escapes from any fuel system line or
hose. Also check fuel tank cap.

cardiagn.com
Note

♦ Light up the components and hoses with a strong floodlight. In

the floodlight, smoke is more visible.
♦ For leak detection in accessible areas, also use ultrasonic
meter or commercially available leak detector spray.
♦ Depending on how long the fault finding takes, it may be nec‐
essary 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, sopen
wage assembly
n AG. Volkswagen AG do
es
opening in vehicle interior.⇒ Vehicle diagnostic
by
Vol tester
k not
gu
ara
ed nte
ris
ho eo
– Renew leaking hoses or components.
au
t ra
ss c
After completing work, perform guided function “checking fuel
ce
e
nl

pt

tank ventilation system for leaks” using vehicle diagnostic tester .

du

an
itte

y li
erm

ab

11.4.2 Schematic overview of activated charcoal filter system

ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
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rp

cu
o

m
f

en
ng

t.
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Cop py
ht. rig
rig ht
py by
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by lksw

395
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Prote AG.
11. Activated charcoal filter system (Passat, CC, Tiguan)
 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passatge2006 n AG. V➤
olk,sw
...agen AG d
wa oes
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive)y V- oEdition 02.2017
lks not
g b ua
ed ran
ris tee
1 - Activated charcoal filter tho
or
au ac
ss
2 - Location of adapter hose -

ce
le
un
KLI 9210/55-1-

pt
an
d
itte

y li
❑ For leak detection in fuel

erm

ab
system

ility
ot p

wit
3 - Activated charcoal filter sol‐

is n

h re
enoid valve 1 - N80-

ole,

spec
urposes, in part or in wh
4 - Breather hose

t to the co
❑ Throttle valve module -
J338-

rrectne
5 - Solenoid valve
❑ For fuel system diagno‐

s
sis pump - V144- .

s o
cial p

f i
6 - Vacuum line

nform
mer

❑ To intake manifold

atio
om

7 - Air filter

n
c

i
or

n thi
e

❑ For fuel system diagno‐

t

sd
va

sis pump - V144- .

i

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pr

cum
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fo

8 - Fuel system diagnostic

en
ng

t.
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pump - V144- t. Cop py
rig
gh ht
9 - Fuel tank yri
p by
co Vo
by lksw
cted
10 - Cap
agen
Prote AG.

11.4.3 Checking vacuum supply of fuel system

diagnostic pump - V144-
Special tools and workshop equipment required
♦ Turbocharger tester - V.A.G 1397A-

♦ T-piece - 251 201 346-

♦ Hose ∅ 6mm

396 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

Note

The fuel system diagnostic pump - V144- is fitted in the rear right
wheel housing behind the wheel housing liner.

– Remove rear right wheel and wheel housing liner.

– Pull off vacuum line -1- from fuel system diagnostic pump -
V144- .
– Connect turbocharger tester G- .V.A.G
Volkswa1397A-
gen AG
with T-piece and
hose ∅ 6mm, between kswavacuum
gen A line -1- and dfuel
oes system diag‐
not
Vol -2-.
nostic pump - V144- gu
by a d ran
ise
– Switch onutmeasuring
ho
r
range I (absolute pressure measure‐
tee
or
ment). ss a ac

ce
le

– Connect vehicle diagnostic tester and start engine.

un

pt
an
d
itte

y li
– On vehicle diagnostic tester , select operating mode Guided
erm

ab
Functions .

ility
ot p

wit
is n

– Select guided function “Checking tank ventilation system for

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11. Activated charcoal filter system (Passat, CC, Tiguan) 397

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

12 Activated charcoal filter system (Golf,

Eos, Scirocco with engine codes CA‐
WA, CAWB, BZB, CGYA, CCZA,
CCZB, CDAA)
Assembly overview - activated charcoal filter system
⇒ page 398
Checking fuel tank breather ⇒ page 399 .

Note

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398 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

1 - Activated charcoal filter

❑ Location: on right in en‐
gine compartment.
2 - Pressure retention valve
with connecting hose
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❑ Ensure firm seating.
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Special tools and workshop equipment required

♦ Hand operated vacuum pump - VAS 6213-

12. Activated charcoal filter system (Golf, Eos, Scirocco with engine codes CAWA, CAWB, BZB, CGYA, CCZA, CCZB,

CDAA) 399
 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

♦ Pressure gauge - VAS 6550-

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– Set ring -1- of hand vacuum pump - VAS 6213- to position

-A- for “vacuum”.
– Operate hand vacuum pump - VAS 6213- several times. There
must be no development of vacuum.
If vacuum builds up:
– Check breather hole on activated charcoal filter
⇒ Item 8 (page 399) for soiling and clean if necessary.
If vacuum does not build up:

400 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Seal breather hole -arrow- and operate vacuum pump again

several times. Vacuum must build up.
If vacuum does not build up:
– Also clamp off hose between activated charcoal filter and ac‐
tivated charcoal filter solenoid valve 1 - N80-
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12. Activated charcoal filter system (Golf, Eos, Scirocco with engine codes CAWA, CAWB, BZB, CGYA, CCZA, CCZB,

CDAA) 401
 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

13 Activated charcoal filter system (Golf,

Eos with engine code CBFA, CCTA,
CCTB)
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402 Rep. gr.20 - Fuel supply system

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❑ For fuel system diagno‐
sis pump - V144- .
8 - Fuel system diagnostic
pump - V144-
❑ Fitting location: In rear right wheel housing beneath liner
❑ Removing and installing ⇒ page 407
❑ Checking fuel system for leaks ⇒ page 408
9 - Connecting cable
❑ From fuel system diagnostic pump - V144- to activated charcoal filter.
❑ Clip onto bracket
10 - Activated charcoal filter
❑ Location: down in spare wheel well
❑ Removing and installing ⇒ page 406
11 - Separation point
❑ Rear right on fuel tank
12 - Exhaust turbocharger
13 - Brake servo
14 - Vacuum pump
15 - Non-return valve
❑ Location: Arrow points in direction of flow

13. Activated charcoal filter system (Golf, Eos with engine code CBFA, CCTA, CCTB) 403
 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

16 - Activated charcoal filter solenoid valve 1 - N80-

❑ Checking ⇒ Vehicle diagnostic tester
17 - Non-return valve
❑ Different versions, allocation ⇒ ETKA (Electronic parts catalogue)
18 - Throttle valve module - J338-
❑ Removing and installing ⇒ page 479
19 - Intake manifold

13.2 Assembly overview - activated charcoal filter system (Golf)

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11 - Connection hose
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❑ For fuel system diagno‐
sis pump - V144- .
13 - 2 Nm
14 - 6 Nm
15 - Fuel system diagnostic pump - V144-
❑ Fitting location: In rear right wheel housing beneath liner
❑ Removing and installing ⇒ page 407
❑ Checking fuel system for leaks ⇒ page 408

404 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

16 - Connector
17 - Vacuum line
❑ From intake manifold

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14 - Fuel tank
15 - Breather hose
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❑ Press release button to pull off
16 - Breather hose
❑ On underbody.
17 - Activated charcoal filter
❑ Location: down in spare wheel well
❑ Removing and installing ⇒ page 406
18 - Connecting cable
❑ Activated charcoal filter / fuel system diagnostic pump - V144-
19 - Vacuum line
❑ To intake manifold

13. Activated charcoal filter system (Golf, Eos with engine code CBFA, CCTA, CCTB) 405
 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

20 - 2 Nm

13.4 Removing and installing activated char‐

coal filter
Special tools and workshop equipment required wage
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– Loosen securing bolts of rear axle -arrows- and unscrew them

approx. 20mm.
– Lower rear axle slowly using engine and gearbox jack -
V.A.G 1383 A- .

406 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Pull off breather lines -A- by pressing release tab.

– Remove bolts -B-.

Note

A reinforcement plate is installed in the Eos. To loosen and tighten

securing bolts -B-, use T-bar and socket 10 mm - 3185- .

– Release retaining tabs -A- using a screwdriver. Turn activated

charcoal filter approx. 90° to right -B- and remove activated
charcoal filter.
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– Install rear axle ⇒ Running gear; Rep. gr. 42 .

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13.5 Removing and installing fuel system di‐

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– Remove rear right wheel housing liner ⇒ General body re‐

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– Install rear right wheel housing liner ⇒ General body repairs,
exterior; Rep. gr. 66 .
Specified torques: ⇒ page 404

13. Activated charcoal filter system (Golf, Eos with engine code CBFA, CCTA, CCTB) 407
 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

13.6 Removing and installing fuel system di‐

agnostic pump - V144- (Eos)
Removing:
– Pull off vacuum line -1-, breather line (air outlet) -2- and breath‐
er line (air inlet) -3-.
– Unscrew nuts -arrows-.
– Remove diagnostic pump with bracket and disconnect elec‐
trical connector.
Installing:
Install in the reverse order of removal, observing the following:
♦ Reconnect electrical connector before securing diagnostic
pump with bracket.
♦ Breather line -2- must audibly engage.
Specified torques: ⇒ page 405

13.7 Checking fuel system for leaks

cardiagn.com
Special tools and workshop equipment required
♦ Fuel system tester (so-called smoke tester) - KLI 9210-
♦ Adapter hose - KLI 9210/55-1-
♦ Vehicle diagnostic tester
♦ Hose clamps to 25 mm - 3094-

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Rep. gr.20 - Fuel supply system
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 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

Preparation of fuel system tester - KLI 9210- :

Note

The fuel system tester - KLI 9210- may differ in appearance de‐
pending on the version.

– Check on fuel system tester - KLI 9210- if 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-.
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13. Activated charcoal filter system (Golf, Eos with engine code CBFA, CCTA, CCTB) 409
 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– 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 “Checking tank ventilation system for

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⇒ page 410 . If no pressure drop can be detected: Check

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⇒ page 414 .

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The minimum pressure was not reached and the available pres‐
sure drops immediately:

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

N80- using a hose clip -arrow-.

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– Repeat check. If the minimum pressure is reached now, renew

activated charcoal filter solenoid valve 1 - N80- .
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If the minimum pressure was again not reached and the available

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pressure drops immediately:

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– Leak in fuel system: Perform “leak detection in fuel system”

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⇒ page 412 .
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– Observe pressure gauge:

If the pressure does not drop at first, perform a pressure retention
test to localise any potential small leaks ⇒ page 410 .

If the pressure drops, clamp off hose to activated charcoal filter

solenoid valve 1 - N80- using a hose clip -arrow-.
– If the pressure does not drop again, renew activated charcoal
filter solenoid valve 1 - N80- .
If the pressure still drops, perform “leak detection in fuel system”
⇒ page 412 .
Pressure retention test

410 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Set valve -D- to “Test”. Set the available pressure to 10 in. H2O
(25 mbar).
– Observe pressure gauge -C- and flow meter -E-. When the
throughput quantity decreases and the pressure increases to
10 in. H2O (25 mbar), the fuel system is filled.

Note

Depending on the filling level of the fuel tank, this process can
take up to 3 minutes.
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– Once pressure has stabilised, set valve -D- to
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– First check activated charcoal filter solenoid valve 1 - N80- for
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leaks. To do this, clamp off hose to activated charcoal filter
hole

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solenoid valve 1 - N80- using a hose clip -arrow-.
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– Repeat pressure test by setting valve -D- again to “Test”.

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– Observe pressure gauge and flow meter. When the through‐

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put quantity decreases and the pressure increases to 10 in.

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H2O (25 mbar), the fuel system is filled.

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– If the pressure does not drop again, renew activated charcoal
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filter solenoid valve 1 - N80- .
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If the pressure still drops, perform “leak detection in fuel system”

⇒ page 412 .
After completing work, perform guided function “checking fuel
tank ventilation system for leaks” using vehicle diagnostic tester .

13. Activated charcoal filter system (Golf, Eos with engine code CBFA, CCTA, CCTB) 411
 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

13.7.1 Leak detection in fuel system

Test specification:
• Procedure for “checking fuel system for leaks” has been com‐
pleted ⇒ page 408 .
• 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
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– Clamp off hose between d bfuel system diagnostic pump - V144-
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and air filter -arrow-.
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412 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Set valve -D- to “Test”.

– Observe pressure gauge -C- and flow meter -E-. When the
throughput quantity decreases and the pressure increases to n AG. Volkswagen AG do
10 in. H2O (25 mbar), the fuel system is filled. olkswage es n
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– Once pressure has stabilised, set valve -D- to “Hold”.rised nte
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• After 5 minutes the pressure must not drop below
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– If the pressure no longer drops, renew fuel system diagnostic

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– Fill fuel system with smoke, set valve -D- again to “Test” for es, in part or in w
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– While fuel system is being filled, press button -I- for smoke
generator for approx. one minute.

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The fuel system is now pressurised and filled with smoke.
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– Check whether smoke escapes from any fuel system line or

hose. Also check fuel tank cap.

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♦ Light up the components and hoses with a strong floodlight. In

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the floodlight, smoke is more visible.

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essary to press the smoke generator button from time to time.
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This ensures that sufficient smoke is present in the fuel sys‐

tem.
♦ To inspect flanges for fuel pump and fuel filter, open assembly
opening in vehicle interior.

– Renew leaking hoses or components.

After completing work, perform guided function “checking fuel
tank ventilation system for leaks” using vehicle diagnostic tester .

13.7.2 Schematic overview of activated charcoal filter system

13. Activated charcoal filter system (Golf, Eos with engine code CBFA, CCTA, CCTB) 413
 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

1 - Activated charcoal filter agen

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2 - Location of adapter hose - d by V gu
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5 - Solenoid valve
❑ For fuel system diagno‐
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6 - Vacuum line
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❑ To intake manifold
7 - Air filter

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❑ For fuel system diagno‐

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13.7.3 Checking vacuum supply of fuel system

diagnostic pump - V144-
Special tools and workshop equipment required
♦ Turbocharger tester - V.A.G 1397A-

♦ T-piece - 251 201 346-

♦ Hose ∅ 6mm

414 Rep. gr.20 - Fuel supply system

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

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♦ Fitting location ofafuel
ut
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♦ Golf: In rear right wheel housing below wheel housing liner.

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♦ Eos: Behind rear right wheel.

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– Remove rear right wheel and wheel housing liner.
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urposes, in part or in wh

– Pull off vacuum line -1- from fuel system diagnostic pump -

t to the co
V144- .
– Connect turbocharger tester - V.A.G 1397A- with T-piece and
hose ∅ 6mm, between vacuum line -1- and fuel system diag‐

rrectne
nostic pump - V144- -2-.

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– Pull off vacuum line -1- from fuel system diagnostic pump -
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– Connect turbocharger tester - V.A.G 1397A- with T-piece and
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hose ∅ 6mm, between vacuum line -1- and fuel system diag‐ co Vo
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nostic pump - V144- -2-. cted agen
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All vehicles:
– 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 “Checking tank ventilation system for

leaks”.
– Initiate test.
– Observe display on turbocharger tester - V.A.G 1397A- while
test is running.
• Pressure must pulsate and must not exceed 0.7 bar (absolute
pressure) during test.
– If pressure exceeds 0.7 bar during test, vacuum supply is too
low. Check vacuum line to intake manifold for possible kinks
or blockages.

13. Activated charcoal filter system (Golf, Eos with engine code CBFA, CCTA, CCTB) 415