Service

Workshop Manual
Crafter 2017 ➤
TGE 2017 ➤
Fuel supply system - Diesel engines
Engine ID
DAT DAU DAV DAS DAS DAW DAW DAU
A A A A B A B B
Edition 03.2018

Service Department. Technical Information

 Service
List of Workshop Manual Repair Groups

Repair Group
00 - Technical data
20 - Fuel supply system

Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
 Crafter 2017 ➤ , TGE 2017 ➤
Fuel supply system - Diesel engines - Edition 03.2018

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety regulations for working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety measures when working on vehicles with start/stop system . . . . . . . . . . . . . . . . . . 2
1.3 Safety precautions when using testers and measuring instruments during a road test . . . . 2
1.4 Safety precautions when working on cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 Safety precautions when working on the SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.6 General safety provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.7 Safety precautions when working on exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Foreign objects in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.6 Routing and attachment of lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.7 Fitting radiator and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.8 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1 Procedure should vehicle be misfueled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.1 Procedure should vehicle be misfueled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1 Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.3 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3 Fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.1 Assembly overview - fuel delivery unit and fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . 26
3.2 Removing and installing fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . 27
3.3 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4 Plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.1 Separating plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.1 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.2 Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6 Accelerator pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.1 Assembly overview - accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.2 Removing and installing accelerator pedal module GX2 . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7 Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.1 Checking fuel system pressurisation pump G6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
8.1 Removing and installing water separator sender G63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Contents i
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Fuel supply system - Diesel engines - Edition 03.2018

ii Contents
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Fuel supply system - Diesel engines - Edition 03.2018

00 – Technical data
1 Safety information
(VRL011383; Edition 03.2018)
⇒ “1.1 Safety regulations for working on fuel supply”, page 1
⇒ “1.2 Safety measures when working on vehicles with start/stop
system”, page 2
⇒ “1.3 Safety precautions when using testers and measuring in‐
struments during a road test”, page 2
⇒ “1.4 Safety precautions when working on cooling system”, page
2
⇒ “1.5 Safety precautions when working on the SCR system”,
page 3
⇒ “1.6 General safety provisions”, page 3
⇒ “1.7 Safety precautions when working on exhaust system”,
page 3

1.1 Safety regulations for working on fuel supply

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

Danger of fire caused by escaping fuel

When the battery is connected and the driver door opens, the door
contact switch activates the fuel pump. Escaping fuel can ignite
and cause a fire.
– Disconnect voltage supply to fuel pump before opening the
fuel system.

Observe the fill level of the fuel tank

♦ Fuel tank must be only partly filled. To find out how much fuel
may remain in the fuel tank, refer to the corresponding work
procedure.
♦ If necessary, drain fuel tank ⇒ page 16 .
♦ Before starting work, the extraction hose of a switched-on ex‐
haust gas extraction system must be laid near to the assembly
opening of the fuel tank.
♦ The exhaust extraction system is used to extract fuel vapours.

1. Safety information 1
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♦ If no exhaust gas extraction system is available, a radial fan

with a displacement greater than 15 m3/h can be used provid‐
ing that motor is not in air flow.
To prevent injuries to persons and destruction of the injection and
glow plug system, the following must be noted:
♦ Always switch off the ignition before connecting or discon‐
necting electrical wiring of injection and glow plug system or
connecting/disconnecting tester cables.
♦ Wash the engine only with the ignition switched off.
♦ When electrical connectors were separated and the engine
was started, read event memory of engine control unit using
⇒ Vehicle diagnostic tester.

1.2 Safety measures when working on vehicles with start/stop system

Risk of injury from engine starting unexpectedly
If the vehicle's start/stop system is activated, the engine could
start unexpectedly. A message in the dash panel insert indicates
whether the start/stop system is activated.
– Deactivate start/stop system by switching off the ignition.

1.3 Safety precautions when using testers and measuring instruments during
a road test
Risk of injury caused by unsecured testing and measuring instru‐
ments
When the front passenger airbag is triggered in an accident, in‐
sufficiently secured testing and measuring instruments become
dangerous projectiles.
– Secure testing and measuring instruments on the rear seat.
Or
– Have a second person operate the test and measuring equip‐
ment on the rear seat.

1.4 Safety precautions when working on cooling system

Scalding from hot coolant
On a warm engine, the cooling system is under high pressure.
Hot steam/hot coolant can escape - risk of scalding.
– Wear protective gloves.
– Wear protective goggles.
– Reduce excess pressure by covering the cap of the coolant
expansion tank with cloths and opening carefully.

2 Rep. gr.00 - Technical data

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1.5 Safety precautions when working on the SCR system

Risk of injury due to reducing agent
The reducing agent may cause eye and skin irritations as well as
injuries to the respiratory system and poisoning.
– Wear protective goggles.
– Wear protective gloves.
– Always wear protective clothes.
– Make sure that a sufficient amount of fresh air is supplied. In
closed areas, switch on the exhaust gas extractor system.

Risk of damage caused by reducing agent

If reducing agent gets onto trim panels and body components, the
reducing agent may solidify after a while and thus damage the
surface.
– Make sure that no reducing agent gets onto the trim panels or
body components.
– If any reducing agent does get onto surfaces, remove it im‐
mediately using water and a cloth.

1.6 General safety provisions

Risk of damage to components
Connecting or disconnecting electric cables or washing the en‐
gine while it is running may damage components.
– Switch off the ignition before connecting or disconnecting elec‐
tric cables.
– Switch off the ignition before washing the engine.

Malfunction caused by air in the fuel supply system

After repair work has been performed on the fuel tank or the fuel
delivery unit, air will be drawn in by the metering pump and con‐
veyed to the auxiliary/supplementary heater. Air in the fuel supply
system may cause the malfunction of the auxiliary/supplementary
heater.
– Fill fuel take-off pipe with fuel.

1.7 Safety precautions when working on exhaust system

Risk of poisoning due to chemical substances
Exhaust gas temperature senders may contain chemical sub‐
stances. There is a risk of poisoning or injuries to respiratory
system.

1. Safety information 3
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– Never open an exhaust gas temperature sender by cutting,

sawing or any other means.
Risk of injury due to hot condensate and particles in the exhaust
system.
The exhaust system could contain hot condensate and/or parti‐
cles. There is a risk of injury to the eyes, skin and respiratory
system, as well as poisoning.
– Always wear protective gloves and eye protection when cut‐
ting the exhaust system.
– When cutting, use an extraction system or otherwise ensure
sufficient ventilation.

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2 Identification
⇒ “2.1 Engine number/engine data”, page 5

2.1 Engine number/engine data

The engine number (engine code and serial number) is located
at the front on the joint -arrow- between engine and gearbox.
In addition, a sticker is attached to the top of the toothed belt guard
-arrow- showing the engine code.
The engine codes have four characters.
The first 3 characters stand for the engine's cubic capacity and
mechanical structure. They are stamped into the cylinder block
together with the serial number.
The fourth character denotes the engine's performance and tor‐
que rating and depends on the engine control unit.
Fitting locations of vehicle data sticker ⇒ Maintenance ; Booklet
10.3 .

Codes DAUB DAUA DAVA

Emissions standard EU 3, 4, 5 and 6 EU 3, 4, 5 and 6 EU 6
Displacement l 1.968 1.968 1.968
Power kW at rpm 75/ 103/ 130/
3500 3500 3600
Torque Nm at rpm 300/ 340/ 410/
2000 2000 2000
Bore Diameter, mm 81.0 81.0 81.0
Stroke mm 95.5 95.5 95.5
Compression ratio 15.5 15.5 15.5
RON Diesel EN 590 Diesel EN 590 Diesel EN 590
Exhaust turbocharger Mono-turbo Mono-turbo Bi-turbo
Firing order 1-3-4-2 1-3-4-2 1-3-4-2
Cylinder 4 4 4

2. Identification 5
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3 Repair notes
⇒ “3.1 Rules for cleanliness”, page 6
⇒ “3.2 General information”, page 6
⇒ “3.3 General repair instructions”, page 7
⇒ “3.4 Foreign objects in engine”, page 7
⇒ “3.5 Contact corrosion”, page 7
⇒ “3.6 Routing and attachment of lines”, page 8
⇒ “3.7 Fitting radiator and condensers”, page 8
⇒ “3.8 Checking vacuum system”, page 8

3.1 Rules for cleanliness

Even slight soiling can cause faults. You must therefore comply
with the following cleanliness rules when working on the fuel sup‐
ply system, injectors or the turbocharger:
♦ Carefully clean connection points and the surrounding area,
and dry thoroughly before opening.
♦ Seal open pipes and connections immediately with clean
plugs for example from the engine bung set - VAS 6122- .
♦ Place removed parts on a clean surface and cover them over.
Use only lint-free cloths.
♦ If repair work cannot be performed immediately, carefully cov‐
er or seal components.
♦ Install clean components only: do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have been stored outside of their packaging
(e.g. in tool boxes).
♦ If system is open, do not work with compressed air. Try not to
move the vehicle.
♦ Protect disconnected electrical connectors from dirt and water,
and reconnect them only when dry.
♦ The components must be clean and dry.

3.2 General information

♦ The engine control unit has a self-diagnosis capability. Before
carrying out repairs and for fault finding, first read event mem‐
ory. Also the vacuum hoses and connections must be checked
(unmetered air).
♦ For trouble-free operation of electrical components, a voltage
of at least 11.5 volts is necessary.
♦ Do not use sealants containing silicone. Particles of silicone
drawn into the engine will not be burnt in the engine and dam‐
age the Lambda probe.
♦ Vehicles are fitted with a crash fuel shut-off circuit. It reduces
the danger of a fire in a crash as the fuel pump is switched off
via the fuel pump relay.
♦ The system also improves the starting characteristics of the
engine. When the driver door is opened, the fuel pump is ac‐
tivated for 2 seconds in order to build up pressure in the fuel
system, observe safety precautions ⇒ page 1 .

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3.3 General repair instructions

♦ Clean tools and workbench etc. before working on injection
system.
♦ The injectors and locations are to be checked before installa‐
tion by means of a visual inspection for damage and dirt. It
must be ensured that the injector bore is clean. If necessary,
clean the injector shaft using a clean cloth. Take care not to
cause any damage (do not use any sharp tools!).
♦ If high-pressure lines are not renewed, they must be labelled
on removal. High-pressure fuel lines must always be re-instal‐
led in their original positions (i.e. on the same cylinder).
♦ Take care not to damage the injectors when removing the old
copper seals.
♦ Check all new O-rings for damage before installing. Lubricate
O-rings with engine oil or assembly oil before installing.
♦ Align high-pressure lines so that they are not subjected to
stress . First tighten all unions hand-tight and then tighten to
torque.
♦ Never attempt to reshape high-pressure fuel lines.
♦ When working on any parts of the high-pressure fuel system,
tools may only be used for loosening and tightening pipe un‐
ions. All other components must always be removed and
installed by hand without using tools or other equipment.
♦ Press the fuel return lines onto the injectors by hand from
above so that they engage audibly on each injector (do not
press in the release pins when doing this). Then, press the
release pin downwards. Pull fuel return lines upwards by hand
to check that they are firmly attached and are not leaking.
♦ Disassembling individual common rail components is not per‐
mitted. The components should be replaced as complete units
if faulty.
♦ Do not carry out any installation work on common rail system
whilst engine is running.
♦ Never attempt to bleed the common rail system by loosening
high-pressure components after starting the engine.
♦ All cable ties which were opened or cut during removal must
be renewed at the same locations.
♦ Fuel hoses in engine compartment must be secured only with
spring-type clips. The use of crimp-type or screw-type clips is
not permissible.

3.4 Foreign objects in engine

♦ To prevent the ingress of foreign bodies during work on the
engine, seal all openings.
♦ Seal openings with suitable bungs from engine bung set - VAS
6122- .

3.5 Contact corrosion

Contact corrosion can occur if non-approved fasteners are used
on the vehicle (bolts, nuts, washers etc.).
For this reason, only connecting elements with a special surface
coating have been fitted.
In addition, rubber, plastic and adhesives are made of non-con‐
ductive materials.

3. Repair notes 7
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If there is any doubt about the suitability of parts, a general rule

is to use new parts ⇒ Electronic Parts Catalogue (ETKA) .
Please note
♦ Use Genuine parts, because they have been are tested and
compatible with aluminium.
♦ Use Volkswagen parts.
♦ Damage resulting from contact corrosion is not covered by the
warranty.

3.6 Routing and attachment of lines

Risk of damage to lines
Lines may become damaged by moving or hot components.
– Route lines in their original positions.
– Ensure there is sufficient clearance to moving or hot compo‐
nents.

3.7 Fitting radiator and condensers

Even if installed correctly, the radiator, the condenser and the
charge air cooler may have small dents in their fins. This does not
mean that these components have been damaged. It is not per‐
missible to renew radiators, charge air coolers or condensers only
because of such minor dents.

3.8 Checking vacuum system

Special tools and workshop equipment required
♦ Hand operated vacuum pump - VAS 6213-

Procedure
– Check all vacuum lines throughout entire vacuum system for:
♦ Cracks
♦ Marten bites
♦ Crushing
♦ Porous areas and other leaks
– Check vacuum line to solenoid valve and from solenoid valve
to relevant component.
– If a fault has been entered in the event memory, make sure to
check not only all vacuum lines leading to the specified com‐
ponent, but also those leading to other components.

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– If pressure cannot be built-up using hand vacuum pump - VAS

6213- or pressure immediately drops again, check hand vac‐
uum pump and connecting hoses for leaks.

3. Repair notes 9
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20 – Fuel supply system

1 Procedure should vehicle be misfu‐
eled
⇒ “1.1 Procedure should vehicle be misfueled”, page 10

1.1 Procedure should vehicle be misfueled

Special tools and workshop equipment required
♦ Fuel identification unit - VAS 6774-

Note

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

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

These instructions are intended as a guide through the individual

work steps by means of a flowchart, while bearing various condi‐
tions in mind.
Was the engine started with the incorrect fuel?
Yes
⇒ “1.1.1 Step 1, engine was started with incorrect fuel”,
page 11 .
No
⇒ “1.1.2 Step 2, engine was not started with incorrect fuel”,
page 11 .

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

page 11
⇒ “1.1.2 Step 2, engine was not started with incorrect fuel”, page
11
⇒ “1.1.3 Step 3, swarf in fuel delivery unit GX1 and fuel tank”,
page 12
⇒ “1.1.4 Step 4, no swarf in fuel delivery unit GX1 and fuel tank”,
page 13
⇒ “1.1.5 Step 5, there are metal particles in high-pressure pump”,
page 13
⇒ “1.1.6 Step 6, there are no metal particles in high-pressure
pump”, page 13

1.1.1 Step 1, engine was started with incorrect

fuel
Procedure
– If fitted, separate electrical connector of supplementary fuel
pump - V393- in engine compartment beneath coolant expan‐
sion tank.
– Remove fuel tank ⇒ page 19 .
– Remove fuel delivery unit - GX1- , and drain ⇒ page 27 .
– Drain fuel pump reservoir of fuel delivery unit - GX1- .
– Drain fuel tank ⇒ page 16 .
– Check fuel tank for metal particles.
– Carry out a visual inspection for foreign bodies and metal par‐
ticles in fuel pump reservoir and on preliminary filter.
Metal particles found?
Yes
⇒ “1.1.3 Step 3, swarf in fuel delivery unit GX1 and fuel tank”,
page 12 .
No
⇒ “1.1.4 Step 4, no swarf in fuel delivery unit GX1 and fuel
tank”, page 13 .

1.1.2 Step 2, engine was not started with in‐

correct fuel
Procedure
– Remove fuel tank ⇒ page 19 .
– Remove fuel delivery unit - GX1- , and drain ⇒ page 27 .
– Check strainer and clean if soiled.
– Drain fuel tank ⇒ page 16 .
Fuel tank completely empty:
– Clean inside of fuel tank with lint-free cloth.
– Install fuel delivery unit - GX1- ⇒ page 27 .
– Install fuel tank ⇒ page 19 .
– Fill fuel tank with 5 litres of diesel fuel.
– Perform bleed fuel system function using ⇒ Vehicle diagnostic
tester.

1. Procedure should vehicle be misfueled 11

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Note

This process takes 130 seconds. Fuel pumps are actuated a total
of three times in the process. The process must not be terminated
prematurely.

– Renew fuel filter ⇒ page 34 .

– Fill up vehicle.
– Carry out road test.

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

and fuel tank
Special tools and workshop equipment required
♦ Diesel extractor - VAS 5226-

Procedure
– Clean fuel delivery unit - GX1- and fuel tank using diesel ex‐
tractor - VAS 5226- .
– Install fuel delivery unit - GX1- ⇒ page 27 .
– Fill fuel tank with 5 litres of diesel fuel.
– Completely empty fuel tank again as described above
⇒ page 11 .
Renew following high-pressure components:
♦ High-pressure pump ⇒ Rep. gr. 23 ; High-pressure pump;
Removing and installing high-pressure pump .
♦ High-pressure lines ⇒ Rep. gr. 23 ; Injectors/fuel rail; Re‐
moving and installing high-pressure lines .
♦ Fuel rail including fuel pressure regulating valve - N276- and
fuel pressure sender - G247- ⇒ Rep. gr. 23 ; Injectors/fuel
rail; Removing and installing fuel rail
♦ Injectors ⇒ Rep. gr. 23 ; Injectors/fuel rail (fuel rail); Removing
and installing injectors
♦ Fuel return lines (overflow oil lines) ⇒ Rep. gr. 23 ; Injector
units/fuel rail; Assembly overview - injectors .
♦ Fuel filter: Renew ⇒ page 34
– Fill up vehicle.
– Bleed fuel system ⇒ Rep. gr. 23 ; Injection system; Filling/
bleeding fuel system .
– Carry out road test.

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1.1.4 Step 4, no swarf in fuel delivery unit -

GX1- and fuel tank
Procedure
– Fill fuel tank with 5 litres of diesel fuel.
– Completely empty fuel tank again as described above
⇒ page 11 .
– Separate electrical connector -1-.
– Unscrew bolts -2-.
– Remove fuel metering valve - N290- -3-.
– Check fuel metering valve - N290- -3- and high-pressure pump
for metal particles.
Metal particles found?
Yes
⇒ “1.1.5 Step 5, there are metal particles in high-pressure
pump”, page 13 .
No
⇒ “1.1.6 Step 6, there are no metal particles in high-pressure
pump”, page 13 .

1.1.5 Step 5, there are metal particles in high-

pressure pump
Procedure
– Replace high-pressure pump ⇒ Rep. gr. 23 ; High-pressure
pump: Removing and installing high-pressure pump .
– Renew high-pressure lines ⇒ Rep. gr. 23 ; Injectors/fuel rail
(fuel rail): Removing and installing high-pressure lines .
– Renew fuel rail including fuel pressure regulating valve - N276-
and fuel pressure sender - G247- ⇒ Rep. gr. 23 ; Injectors/
fuel rail: Removing and installing fuel rail .
– Renew injectors ⇒ Rep. gr. 23 ; Injectors/fuel rail; Removing
and installing injectors
– Renew fuel return lines ⇒ Rep. gr. 23 ; Injector units/fuel rail;
Assembly overview - fuel rail
– Renew fuel filter ⇒ page 34 .
– Fill up vehicle.
– Fill/bleed fuel system ⇒ Rep. gr. 23 ; Injection system; Filling/
bleeding fuel system .
– Carry out road test.

1.1.6 Step 6, there are no metal particles in

high-pressure pump
Procedure
– Replace high-pressure pump ⇒ Rep. gr. 23 ; High-pressure
pump: Removing and installing high-pressure pump .
– Renew fuel filter ⇒ page 34 .
– Fill/bleed fuel system ⇒ Rep. gr. 23 ; Injection system; Filling/
bleeding fuel system .
– Fill up vehicle.

1. Procedure should vehicle be misfueled 13

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– Carry out road test.

14 Rep. gr.20 - Fuel supply system

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2 Fuel
⇒ “2.1 Assembly overview - fuel tank”, page 15
⇒ “2.2 Emptying fuel tank”, page 16
⇒ “2.3 Removing and installing fuel tank”, page 19

2.1 Assembly overview - fuel tank

1 - Fuel
❑ Removing and installing
⇒ page 19
2 - Bolt
❑ 8 Nm +90°
3 - Clip
4 - Retaining strap
5 - Cap
❑ Renew seal if damaged.
6 - Fuel line
❑ From metering pump -
V54- to auxiliary heater
❑ Do not kink
❑ Depending on equip‐
ment ⇒ Auxiliary heater,
supplementary heater;
Rep. gr. 82 ; Fuel sup‐
ply system; Overview of
fitting locations - fuel
supply system .
❑ Separating plug-in con‐
nectors ⇒ page 29
7 - Fuel return line
❑ From engine
❑ Do not kink
❑ Disconnect plug-in con‐
nectors ⇒ page 29
8 - Fuel supply line
❑ To engine
❑ Do not kink
❑ Disconnect plug-in con‐
nectors ⇒ page 29
9 - Union nut
❑ Specified torque ⇒ Item 7 (page 26)
10 - Seal
❑ Renew after removal
❑ Insert dry.
❑ Moisten with fuel only when installing fuel delivery unit - GX1-
11 - Fuel delivery unit - GX1-
❑ With fuel system pressurisation pump - G6- .
❑ With integrated fuel filter; cannot be renewed individually
❑ With integrated pressure limiting valve; cannot be renewed individually

2. Fuel 15
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❑ Assembly overview ⇒ page 26
❑ Removing and installing ⇒ page 27
12 - Securing strap
❑ Observe installation position
❑ Ensure firm seating
13 - Bolt
❑ Renew after removal
❑ 20 Nm +90°

2.2 Emptying fuel tank

⇒ “2.2.1 Emptying fuel tank when fuel pump is intact”,
page 16
⇒ “2.2.2 Emptying fuel tank if it is more than 3/4 full:”, page 17
⇒ “2.2.3 Emptying fuel tank if it is less than 3/4 full”, page 19

2.2.1 Emptying fuel tank when fuel pump is

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

♦ Adapter for fuel extraction - VAS 5190-

16 Rep. gr.20 - Fuel supply system

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Procedure
Prepare special tool as follows

Note

If the fuel extraction unit - VAS 5190- is still fitted with the extrac‐
tion hose with a fixed tip, the extraction hose must be replaced
with the version with a screw-in tip.

– Unscrew tip -1- from extraction hose of fuel extractor - VAS

5190- .
– Screw fuel extraction adapter - VAS 5190 /2- -2- from fuel ex‐
traction adapter set - VAS 5190 /10- onto extraction hose.

– Switch off ignition.

CAUTION
The fuel system is pressurised.
Danger of injury caused by fuel spray.
– Wear protective goggles.
– Wear protective gloves.
– To release pressure, wrap a clean cloth around the connec‐
tion and carefully loosen the connection.

– Separate fuel return line -1- and fuel supply line -2-.
– Collect escaping fuel with a cleaning cloth.

– Connect extraction hose -2- of fuel extractor - VAS 5190- -3-

with fuel supply line -1-.

Note

The fuel system pressurisation pump - G6- is actuated by ⇒ Ve‐

hicle diagnostic tester, and the fuel tank is emptied in the process.

– Connect ⇒ Vehicle diagnostic tester.

– Use ⇒ Vehicle diagnostic tester to drain fuel tank.
– Repeat the function if necessary.
– Open shut-off tap on fuel extractor - VAS 5190- until fuel tank
is emptied.

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

full:
Special tools and workshop equipment required

2. Fuel 17
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♦ Fuel extraction unit - VAS 5190 A-

Procedure
– Make a mark -arrow- at dimension -a- from end of extraction
hose of fuel extractor - VAS 5190- .
• Dimension -a- on extraction hose: 660 mm

– Open driver door -1-.

– Open tank flap unit -2-.
– Clean area around fuel filler neck.
– Unscrew filler cap -3-.
– Secure earth wire of fuel extractor - VAS 5190- to a bare metal
part of the body.

– Insert extraction hose -1- of fuel extractor - VAS 5190- into fuel
tank until mark -arrow- aligns with filler neck -2-.
– Drain fuel tank via filler neck as far as possible.

Note

♦ There is a non-return valve -3- in the fuel tank at the lower end
of the filler neck. The valve must not be damaged by the ex‐
traction hose -1-. Therefore push extraction hose -1- into filler
neck only as far as marking -arrow-.
♦ If the extraction hose -1- catches on the non-return valve -3-
when being extracted, do not apply force to pull out the ex‐
traction hose -1-.
♦ In this case, remove the fuel delivery unit - GX1- and open the
non-return valve -3- manually. Ensure that your arm does not
come into contact with fuel.

– Pull extraction hose out carefully.

18 Rep. gr.20 - Fuel supply system

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

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

Procedure
– Remove fuel delivery unit - GX1- ⇒ page 27 .
– Completely empty the fuel tank -2- using the extraction hose
-1- of fuel extractor - VAS 5190- through the opening of the
fuel delivery unit - GX1- .

2.3 Removing and installing fuel tank

⇒ “2.3.1 Removing and installing fuel tank”, page 19
⇒ “2.3.2 Lower fuel tank.”, page 22

2.3.1 Removing and installing fuel tank

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

2. Fuel 19
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♦ Engine and gearbox jack - VAS 6931-

♦ Engine bung set - VAS 6122-

♦ Tensioning strap
Removing
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .
– Open driver door.
– Remove lower B-pillar cover ⇒ General body repairs, exterior;
Rep. gr. 66 ; Mouldings/trims/extensions; Removing and in‐
stalling cover .
– Open tank flap -1-.
– Unscrew filler cap -3-.
– Unscrew bolts -4-.
– Remove filler neck bowl -2-.

– Unscrew bolt -1- on filler neck -2-.

20 Rep. gr.20 - Fuel supply system

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– Unscrew bolt -1-.

– Screw on filler cap again.
– Drain tank for reducing agent ⇒ Rep. gr. 26 ; SCR system
(selective catalytic reduction); Draining tank for reducing
agent .
– If fitted, remove underbody cover ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody cover; Removing and in‐
stalling underbody cladding .

CAUTION
Risk of injury caused by escaping reducing agent.
The reducing agent may cause eye and skin irritations as well
as injuries to the respiratory system and poisoning.
– Wear protective goggles.
– Wear protective gloves.
– Always wear protective clothes.
– Make sure that a sufficient amount of fresh air is supplied.
In closed areas, switch on the exhaust gas extractor system.

– Disconnect quick-release coupling -1-.

– Remove filler pipe -2- upwards.
– Seal off all open lines and connections with clean plugs from
engine bung set - VAS 6122- .
– Use tensioning straps to secure engine and gearbox jack -
VAS 6931- from falling.

– Place engine and gearbox jack - VAS 6931- -2- under fuel tank
-1-.

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Note

♦ For reasons of clarity, the fuel tank is shown without the engine
and gearbox jack - VAS 6931- .
♦ The aid of a second mechanic is required to remove the fuel
tank.

– Unscrew bolts -1-.

– Remove accessible tensioning straps -3- from fuel tank -2-.

Note

Carefully lower the fuel tank with engine and gearbox jack - VAS
6931- until the fuel lines above fuel tank are accessible.

– If fitted, unclip fuel lines -1- from attachment -arrow-.

– If fitted, unclip fuel lines -2- and -3- from attachments
-arrows-.

Note

Continue lowering fuel tank -4- with engine and gearbox jack -
VAS 6931- until the connector and fuel lines on the fuel delivery
unit - GX1- can be disconnected.

– If fitted, separate fuel line -3-.

– Disconnect fuel line -1-.
– Disconnect fuel line -2-.
– Separate electrical connector -4-.
– Lower fuel tank further with engine and gearbox jack - VAS
6931- .
– Loosen tensioning strap.
– Lift down the fuel tank from the engine and gearbox jack - VAS
6931- with the help of a second mechanic.
– Seal open fuel hoses and connections with clean plugs from
engine bung set - VAS 6122- .
Installing
Install in reverse order of removal, observing the following:
Torque settings
♦ SCR system (Selective Catalytic Reduction); Assembly over‐
view - reducing agent tank ⇒ Rep. gr. 26 ; SCR system
(Selective Catalytic Reduction); Assembly overview - reducing
agent tank
♦ ⇒ “2.1 Assembly overview - fuel tank”, page 15

2.3.2 Lower fuel tank.

Special tools and workshop equipment required

22 Rep. gr.20 - Fuel supply system

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♦ Torque wrench - V.A.G 1331-

♦ Engine and gearbox jack - VAS 6931-

♦ Engine bung set - VAS 6122-

♦ Tensioning strap

2. Fuel 23
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Procedure
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .
– Open driver door.
– Open tank flap -1-.
– Unscrew filler cap -3-.
– Unscrew bolts -4-.
– Remove filler neck bowl -2-.

– Unscrew bolt -1- on filler neck -2-.

– Unscrew bolt -1-.

– Screw on filler cap again.
– Drain tank for reducing agent ⇒ Rep. gr. 26 ; SCR system
(selective catalytic reduction); Draining tank for reducing
agent .
– If fitted, remove underbody cover ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody cover; Removing and in‐
stalling underbody cladding .

CAUTION
Risk of injury caused by escaping reducing agent.
The reducing agent may cause eye and skin irritations as well
as injuries to the respiratory system and poisoning.
– Wear protective goggles.
– Wear protective gloves.
– Always wear protective clothes.
– Make sure that a sufficient amount of fresh air is supplied.
In closed areas, switch on the exhaust gas extractor system.

24 Rep. gr.20 - Fuel supply system

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– Disconnect quick-release coupling -1-.

– Remove filler pipe -2- upwards.
– Seal off all open lines and connections with clean plugs from
engine bung set - VAS 6122- .
– Use tensioning straps to secure engine and gearbox jack -
VAS 6931- from falling.

– Place engine and gearbox jack - VAS 6931- -2- under fuel tank
-1-.

Note

For reasons of clarity, the fuel tank is shown without the engine
and gearbox jack - VAS 6931- .

– Unscrew bolts -1-.

– Remove accessible tensioning straps -3- from fuel tank -2-.
– Carefully lower the fuel tank with engine and gearbox jack -
VAS 6931- until the fuel lines above fuel tank are accessible.
Torque settings
♦ SCR system (Selective Catalytic Reduction); Assembly over‐
view - reducing agent tank ⇒ Rep. gr. 26 ; SCR system
(Selective Catalytic Reduction); Assembly overview - reducing
agent tank
♦ ⇒ “2.1 Assembly overview - fuel tank”, page 15

2. Fuel 25
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3 Fuel delivery unit, fuel gauge sender

⇒ “3.1 Assembly overview - fuel delivery unit and fuel gauge
sender”, page 26
⇒ “3.2 Removing and installing fuel delivery unit, fuel gauge send‐
er”, page 27
⇒ “3.3 Removing and installing fuel gauge sender G ”,
page 28

3.1 Assembly overview - fuel delivery unit and fuel gauge sender

1 - Fuel return line

❑ Do not kink
❑ Disconnect plug-in con‐
nectors ⇒ page 29
2 - Fuel supply line
❑ Do not kink
❑ Disconnect plug-in con‐
nectors ⇒ page 29
3 - Fuel line
❑ From metering pump -
V54- to auxiliary heater
❑ Do not kink
❑ Depending on equip‐
ment ⇒ Auxiliary heater,
supplementary heater;
Rep. gr. 82 ; Fuel sup‐
ply system; Overview of
fitting locations - fuel
supply system .
❑ Disconnect plug-in con‐
nectors ⇒ page 29
4 - Fuel delivery unit - GX1-
❑ With fuel system pres‐
surisation pump - G6- .
❑ With integrated fuel fil‐
ter; cannot be renewed
individually
❑ With integrated pres‐
sure limiting valve; can‐
not be renewed individ‐
ually
❑ Removing and installing
⇒ page 27
5 - Fuel gauge sender - G-
❑ Removing and installing ⇒ page 28
6 - Seal
❑ Renew after removal
❑ When installing, fit dry in fuel tank opening.
❑ Moisten with fuel only when installing fuel delivery unit - GX1-
7 - Union nut
❑ 110 Nm
8 - Electrical connector

26 Rep. gr.20 - Fuel supply system

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3.2 Removing and installing fuel delivery

unit, fuel gauge sender
Special tools and workshop equipment required
♦ Key for union nut - 3217-

♦ Torque wrench - V.A.G 1332-

Removing
– Remove fuel tank ⇒ page 19 .
– Unscrew union nut -3- with union nut tool - 3217- -1- and
ratchet wrench -2-.

Note

When removing the fuel delivery unit - GX1- , make sure that the
float arm of the fuel gauge sender - G- is not bent.

– Carefully pull out fuel delivery unit - GX1- with fuel gauge
sender - G- through opening of fuel tank.
– Turn and tilt it as necessary while doing so.
– Place a cloth underneath the fuel delivery unit - GX1- to catch
any escaping fuel.

3. Fuel delivery unit, fuel gauge sender 27

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Installing
Install in reverse order of removal, observing the following:
– Insert seal for fuel delivery unit - GX1- dry into opening of fuel
tank.
– Coat inner side of seal with fuel.

Note

♦ When inserting the fuel delivery unit - GX1- , ensure that the
fuel gauge sender - G- is not bent.
♦ When tightening the union nut, be careful not to damage or
crush the seal.

Mark on flange -1- must align with mark on fuel tank -arrow-.
Torque settings
♦ ⇒ “3.1 Assembly overview - fuel delivery unit and fuel gauge
sender”, page 26

3.3 Removing and installing fuel gauge

sender - G-
Removing
– Remove fuel delivery unit - GX1- ⇒ page 27 .
– Remove connector -1- for fuel gauge sender - G- -3-.
– Unclip electrical wires from retainer -4-.
– Release retaining tab -arrows- by pulling off fuel gauge sender
- G- -3- upwards from fuel delivery unit - GX1- -2-.
Installing
Install in reverse order of removal.

28 Rep. gr.20 - Fuel supply system

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4 Plug-in connectors
⇒ “4.1 Separating plug-in connectors”, page 29

4.1 Separating plug-in connectors

Assignment of plug-in connectors

Note

♦ The plug-in connectors for fuel, vacuum and breather lines are
colour coded. There is either a coloured dot on the plug-in
connector or the release button is of the respective colour
⇒ page 29 .
♦ Plug-in connectors for fuel lines must engage »audibly« when
joined.
♦ Ensure plug-in connector is secured properly by pulling it.

Colour assignment
Plug-in connector Colour code on plug-in connector
Fuel supply black
Fuel return line blue
Breather White, beige
Vacuum green

Version 1
Plug-in connector with release buttons -arrows- on right and left:

4. Plug-in connectors 29
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Open
– Push plug-in connector -1- in -direction of arrow A-.
– Press and hold release buttons.
– Pull plug-in connector -1- off fuel line -2- in
-direction of arrow B-.
Note colour assignment during installation ⇒ page 29 .

Version 2
Plug-in connector with pull-release mechanism -arrow-.

Open
– Push plug-in connector -1- in -direction of arrow A-.
– Pull pull-release mechanism -2- in -direction of arrow B-.
– Pull plug-in connector -1- off fuel line -3- in
-direction of arrow B-.
Note colour assignment during installation ⇒ page 29 .

30 Rep. gr.20 - Fuel supply system

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Version 3
Plug-in connector with button in front -arrow-
Open
– Press release button -arrow- and pull off plug-in connectors.
Note colour assignment during installation ⇒ page 29 .

Version 4
Plug-in connector with release button -arrows- on right and left:
Open
– Push plug-in connector in -direction of arrow A-.
– Press release buttons -arrows- and pull off plug-in connector.
Note colour assignment during installation ⇒ page 29 .

Version 5
Plug-in connector with release buttons -arrows- on right and left:
Open
– Press release buttons -arrows- and pull off plug-in connector.
Note colour assignment during installation ⇒ page 29 .

Version 6
Plug-in connector with release buttons -arrows- on right and left:
Open
– Push plug-in connector -1- in -direction of arrow-, and hold it
in that position.
– Press release buttons -arrows- and pull off plug-in connector.
Note colour assignment during installation ⇒ page 29 .

4. Plug-in connectors 31
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Version 7
Plug-in connector -1- with release buttons -2- on right and left:
Open
– Push plug-in connector -1- in -direction of arrow A-, and hold
it in that position.
– Press release button -2- in -direction of arrow B- and pull off
plug-in connector -1-.
Note colour assignment during installation ⇒ page 29 .

32 Rep. gr.20 - Fuel supply system

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5 Fuel filter
⇒ “5.1 Assembly overview - fuel filter”, page 33
⇒ “5.2 Removing and installing fuel filter”, page 34

5.1 Assembly overview - fuel filter

1 - Fuel filter
❑ Removing and installing
⇒ page 34
2 - Fuel filter support
❑ On some equipment
versions with crash pro‐
tection
❑ Removing and installing
⇒ page 36
3 - Bolts
❑ Qty. 2
❑ 12 Nm
4 - Bolt
❑ 8 Nm
5 - Clip
6 - Bleeder valve
❑ Depending on equip‐
ment
❑ 8 Nm
7 - Seal
❑ Depending on equip‐
ment
❑ Renew after removal
8 - Water separator sender -
G63-
❑ Depending on equip‐
ment
❑ Removing and installing
⇒ page 46
9 - Cover
❑ On some equipment
versions with crash protection
❑ Removing and installing ⇒ page 36
10 - Bolts
❑ Qty. 4
❑ 8 Nm
11 - Bracket
❑ For fuel lines

5. Fuel filter 33
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5.2 Removing and installing fuel filter

⇒ “5.2.1 Removing and installing fuel filter with water separator
sender G63 ”, page 34
⇒ “5.2.2 Removing and installing fuel filter without water separator
sender G63 ”, page 35
⇒ “5.2.3 Removing and installing bracket for fuel filter”,
page 36

5.2.1 Removing and installing fuel filter with

water separator sender - G63-
Special tools and workshop equipment required
♦ Drip tray for workshop hoist - VAS 6208-

♦ Torque wrench - V.A.G 1783-

Removing
– Place drip tray for workshop hoist - VAS 6208- beneath fuel
filter.

CAUTION
The fuel system is pressurised.
Danger of injury caused by fuel spray.
– Wear protective goggles.
– Wear protective gloves.
– To release pressure, wrap a clean cloth around the connec‐
tion and carefully loosen the connection.

– Disconnect fuel line -1- on fuel filter -3-.

– Disconnect fuel line -2- on fuel filter -3-.

34 Rep. gr.20 - Fuel supply system

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– Unclip electrical wire -3-.

– Unclip fuel lines -4-.
– Unscrew bolts -2-.

Note

The water separator sender - G63- is screwed into the fuel filter
from underneath. When laying the fuel filter aside, consider the
length of the electrical wire of the water separator sender - G63- .

– Move fuel filter -1- with bracket clear to one side.

– Disconnect connector -2- of water separator sender - G63- at
fuel filter -1-.
– Remove fuel filter -1- with bracket.
Change fuel filter
– Remove water separator sender - G63- ⇒ page 46 .
– Remove bracket for fuel filter ⇒ page 36 .
Installing
Install in reverse order of removal, observing the following:
– Renew seal for water separator sender - G63- .
– Bleed fuel system ⇒ Rep. gr. 23 ; Injection system; Filling/
bleeding fuel system .
Torque settings
♦ ⇒ “5.1 Assembly overview - fuel filter”, page 33

5.2.2 Removing and installing fuel filter with‐

out water separator sender - G63-
Special tools and workshop equipment required
♦ Drip tray for workshop hoist - VAS 6208-

5. Fuel filter 35
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♦ Torque wrench - V.A.G 1783-

Removing
– Place drip tray for workshop hoist - VAS 6208- beneath fuel
filter.

CAUTION
The fuel system is pressurised.
Danger of injury caused by fuel spray.
– Wear protective goggles.
– Wear protective gloves.
– To release pressure, wrap a clean cloth around the connec‐
tion and carefully loosen the connection.

– Disconnect fuel line -1- on fuel filter -3-.

– Disconnect fuel line -2- on fuel filter -3-.

– Unclip electrical wire -3-.

– Unclip fuel lines -4-.
– Unscrew bolts -2-.
Change fuel filter
– Remove bracket for fuel filter ⇒ page 36 .
Installing
Install in reverse order of removal, observing the following:
– Bleed fuel system ⇒ Rep. gr. 23 ; Injection system; Filling/
bleeding fuel system .
Torque settings
♦ ⇒ “5.1 Assembly overview - fuel filter”, page 33

5.2.3 Removing and installing bracket for fuel

filter
Special tools and workshop equipment required

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♦ Torque wrench - V.A.G 1783-

Removing
– Remove fuel filter ⇒ page 35 .
– Unscrew bolts -arrows-, and remove bracket -4- and (if fitted)
crash protection.
– Unscrew bolt -1-. Remove bracket -3- from fuel filter -2-.
Installing
Install in reverse order of removal, observing the following:

Note

If a new bracket for the fuel filter is installed, all fastening elements
must be fitted on the bracket.

Torque settings
♦ ⇒ “5.1 Assembly overview - fuel filter”, page 33

5. Fuel filter 37
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6 Accelerator pedal
⇒ “6.1 Assembly overview - accelerator module”, page 38
⇒ “6.2 Removing and installing accelerator pedal module GX2 ”,
page 38

6.1 Assembly overview - accelerator module

1 - Bolts
❑ Qty. 2
❑ 6 Nm
2 - Gas pedal module - GX2-
❑ Removing and installing
⇒ page 38
3 - Support
❑ for accelerator pedal
module - GX2-

6.2 Removing and installing accelerator

pedal module - GX2-
Special tools and workshop equipment required

38 Rep. gr.20 - Fuel supply system

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♦ Torque wrench - V.A.G 1783-

Removing
– Separate electrical connector -2-.
– Unscrew bolts -1-.
– Remove accelerator module - GX2- -3-.
Installing
Install in reverse order of removal, observing the following:
Torque settings
♦ ⇒ “6.1 Assembly overview - accelerator module”, page 38

6. Accelerator pedal 39
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7 Fuel pump
⇒ “7.1 Checking fuel system pressurisation pump G6 ”,
page 40

7.1 Checking fuel system pressurisation

pump - G6-
⇒ “7.1.1 Checking fuel pressure”, page 40
⇒ “7.1.2 Checking fuel delivery rate”, page 43

7.1.1 Checking fuel pressure

Special tools and workshop equipment required
♦ Drip tray for workshop hoist - VAS 6208-

♦ Hose adapter set - VAS 6551/5-

♦ Pressure gauge - VAS 6551-

♦ Vehicle diagnostic tester
Prerequisites for check
• The event memory of the engine control unit contains no event
entry relating to the voltage supply to the fuel pump.
• Battery charger connected ⇒ Electrical system; Rep. gr. 27 ;
Battery; Charging battery .
• Fuse for fuel pump OK. Fuse assignment ⇒ Current flow dia‐
grams, Electrical fault finding and Fitting locations
• Fuel filter OK.
• Visual check carried out
• Fuel tank at least 3/4 full
• Ignition off

40 Rep. gr.20 - Fuel supply system

 Crafter 2017 ➤ , TGE 2017 ➤
Fuel supply system - Diesel engines - Edition 03.2018

Test sequence

CAUTION
The fuel system is pressurised.
Danger of injury caused by fuel spray.
– Wear protective goggles.
– Wear protective gloves.
– To release pressure, wrap a clean cloth around the connec‐
tion and carefully loosen the connection.

– Place drip tray - VAS 6208- beneath vehicle.

– Disconnect fuel line -1- from fuel filter -2-.
– Collect escaping fuel with a cleaning cloth.

– Connect pressure tester - VAS 6551- -4- to hose adapter - VAS

6551/5-4- -5- and fuel filter.
– Connect pressure tester - VAS 6551- -4- to hose adapter - VAS
6551/5-3- -3-.
– Fit connection of hose adapter - VAS 6551/5-3- -2- to fuel line
-1-.

7. Fuel pump 41
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Fuel supply system - Diesel engines - Edition 03.2018

– Switch on pressure tester - VAS 6551- -1- by pressing On/

Off button.

– Open shut-off taps -A- and -B- of pressure tester - VAS 6551-
-1-.
– Close shut-off valve -C-.
– Actuate with fuel system pressurisation pump - G6- with ⇒ Ve‐
hicle diagnostic tester.

Note

The fuel pump will be activated for 30 seconds.

– Read pressure shown by pressure tester - VAS 6551- . Spec‐

ification is 4.5 bar at least.
– Start engine and allow to idle.
– Read pressure shown by pressure tester - VAS 6551- . Spec‐
ification is 4.5 bar at least.
– Place pressure tester - VAS 6551- onto windscreen so that it
can be read from inside vehicle.
– Increase idling speed to 2500 rpm.
– Read pressure shown by pressure tester - VAS 6551- . Spec‐
ification is 4.5 bar at least.

If pressure is not reached

Note

If the specified pressure is again not achieved, perform a meas‐

urement directly on fuel delivery unit - GX1- .

– Lower fuel tank ⇒ page 22 .

– Disconnect fuel line -2- from fuel delivery unit - GX1- -1-.

– Connect pressure tester - VAS 6551- -4- to hose adapter - VAS

6551/5-4- -5- and fuel delivery unit - GX1- -1-.
– Connect pressure tester - VAS 6551- -4- to hose adapter - VAS
6551/5-3- -3-.
– Connect hose adapter - VAS 6551/5-3- -3- to fuel line -2-.

42 Rep. gr.20 - Fuel supply system

 Crafter 2017 ➤ , TGE 2017 ➤
Fuel supply system - Diesel engines - Edition 03.2018

– Switch on pressure tester - VAS 6551- -1- by pressing On/

Off button.

– Open shut-off taps -A- and -B- of pressure tester - VAS 6551-
-1-.
– Close shut-off valve -C-.
– Actuate with fuel system pressurisation pump - G6- with ⇒ Ve‐
hicle diagnostic tester.

Note

The fuel pump will be activated for 30 seconds.

– Read pressure shown by pressure tester - VAS 6551- . Spec‐

ification is 4.5 bar at least.
– Start engine and allow to idle.
– Read pressure shown by pressure tester - VAS 6551- . Spec‐
ification is 4.5 bar at least.
– Place pressure tester - VAS 6551- onto windscreen so that it
can be read from inside vehicle.
– Increase idling speed to 2500 rpm.
– Read pressure shown by pressure tester - VAS 6551- . Spec‐
ification is 4.5 bar at least.

If specification is not attained

– Checking fuel delivery rate ⇒ page 43 .
If the specifications are still not attained:
– Renew fuel delivery unit - GX1- ⇒ page 27 .
If specification is attained
– Remove pressure tester - VAS 6551- , and re-connect fuel
supply line.

Note

If the pressure tester - VAS 6551- -1- is to be removed, open the

shut-off tap -C-, and release remaining pressure. To do this, hold
the hose of the shut-off tap -C- in a measuring container.

7.1.2 Checking fuel delivery rate

Special tools and workshop equipment required
♦ Drip tray for workshop hoist - VAS 6208-

7. Fuel pump 43
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Fuel supply system - Diesel engines - Edition 03.2018

♦ Hose adapter set - VAS 6551/5-

♦ Pressure gauge - VAS 6551-

♦ Vehicle diagnostic tester
Test conditions:
• Delivery pressure of fuel pump checked beforehand.
• Connect charger or battery voltage above 12.5 volts.
• Fuel tank at least 3/4 full
Test sequence
– Lower fuel tank ⇒ page 19 .

CAUTION
The fuel system is pressurised.
Danger of injury caused by fuel spray.
– Wear protective goggles.
– Wear protective gloves.
– To release pressure, wrap a clean cloth around the connec‐
tion and carefully loosen the connection.

– Place drip tray - VAS 6208- beneath vehicle.

– Disconnect fuel supply line -2- from fuel delivery unit - GX1-
-1-.
– Collect escaping fuel with a cleaning cloth.

– Connect pressure tester - VAS 6551- -1- with connection cable

- VAS 6551/5-4- -4- to fuel delivery unit - GX1- .
– Connect connection cable - VAS 6551/5-3- -2- to pressure
tester - VAS 6551- .
– Extend connection cable - VAS 6551/5-3- -2- using hose - VAS
6551/2- , and hold end of hose - VAS 6551/2- in measuring
beaker -3-.

Note

Ensure hose connections are fitted securely.

44 Rep. gr.20 - Fuel supply system

 Crafter 2017 ➤ , TGE 2017 ➤
Fuel supply system - Diesel engines - Edition 03.2018

– Open shut-off taps -A- and -B- of pressure tester - VAS 6551-
-1- in direction of flow.
– Close shut-off valve -C-.
– Switch on pressure tester - VAS 6551- by pressing On/Off
button.
– Carry out “fuel pump activation”.
– Select “Check delivery rate”.

Note

The fuel pump is now activated for 30 seconds.

– Slowly close shut-off tap -B- until back pressure of 4 bar is

reached.
– Drain measuring container.
– Carry out guided function “Activating fuel pump” again.
– Select function “Check delivery rate”.

Note

The fuel pump is now activated for 30 seconds.

Minimum flow rate according to specification: > 1.3 l/30 seconds.

If specification is not attained

– Perform the fuel delivery rate check one more time.
If the specifications are still not attained:
– Renew fuel delivery unit - GX1- ⇒ page 27 .
If specification is attained
– Remove pressure tester - VAS 6551- , and re-connect fuel
supply line.

Note

If the pressure tester - VAS 6551- -1- is to be removed, open the

shut-off tap -C-, and release remaining pressure. To do this, hold
the hose of the shut-off tap -C- in a measuring container.

7. Fuel pump 45
 Crafter 2017 ➤ , TGE 2017 ➤
Fuel supply system - Diesel engines - Edition 03.2018

8 Senders and sensors

⇒ “8.1 Removing and installing water separator sender G63 ”,
page 46

8.1 Removing and installing water separator

sender - G63-
Special tools and workshop equipment required
♦ Drip tray for workshop hoist - VAS 6208-

Removing
– Remove fuel filter ⇒ page 34 .

Note

Catch any escaping fuel with a drip tray - VAS 6208- or a cloth.

– Unscrew water separator sender - G63- -2- from fuel filter

-1-.
Installing
Install in reverse order of removal, observing the following:
– Renew seal for water separator sender - G63- .
Torque settings
♦ ⇒ “5.1 Assembly overview - fuel filter”, page 33

46 Rep. gr.20 - Fuel supply system