Fuel Supply System

Service
Workshop Manual
CC 2012 ➤
Passat 2011 ➤
Passat Variant 2011 ➤
Fuel supply system - diesel engines
IEngine ID
CAY CFFA CFFB CFG CLLA CFG CUV CUW
C
Edition 05.2019
B C C A
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
20 - Fuel supply system agen
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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.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2019 Volkswagen AG, Wolfsburg D3E803ECA74

CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
Fuel supply system - diesel engines - Edition 05.2019
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 a 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 the SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Rules for cleanliness when working on auxiliary/supplementary heater and fuel system . . 5
4 Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Pipe/wire routing and attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1 Procedure shouldevehicle AG. Volkbe
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1.1 Step 1, engine Volkswwas started with incorrect nofuel
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1.2 Step r2, isedengine was not started with incorrect fuel
ara
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................................ 9
1.3 Steputho 3, there are metal particles in fuel delivery unit or and fuel tank . . . . . . . . . . . . . . . . . . 11
a ac
1.4 ss
Step 4, there are no metal particles in fuel delivery unit or fuel tank . . . . . . . . . . . . . . . . . . 12
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1.5 Step 5, there are metal particles in high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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1.6 Step 6, there are no metal particles in high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . 13

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2 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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2.1 Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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2.2 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

hole
spec
2.3 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

es, in part or in w
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3 Fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3.1 Assembly overview - fuel delivery unit/fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.2 Removing and installing fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . 37
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3.3 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

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3.4 Removing and installing fuel gauge sender 2 G169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4 Plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
nform
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4.1 Separating plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

m
5 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
com
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5.1 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

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5.2 Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

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5.3 Fuel hoses in the engine compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

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6 Accelerator pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
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6.1 Assembly overview - accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
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6.2 Removing and installing accelerator pedal module GX2 . . . . . . . . . . . . . . . . . . . . . . . . . . 57
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7 Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
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7.1 Checking fuel system pressurisation pump G6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7.2 Removing and installing suction-jet pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Contents i
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ii Contents
00 – Technical data
1 Safety information
(VRL013020; Edition 05.2019)
⇒ “1.1 Safety regulations for working on fuel supply”, page 1
⇒ “1.2 Safety measures when working on vehicles with a 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 the SCR system”,
page 2
1.1 Safety regulations for working on fuel supply

Risk of injury from highly pressurised fuel.
The fuel system is pressurised. Injury from fuel spray possible.
Before opening the fuel system:
– Wear protective goggles.
– Wear protective gloves. n AG. Volkswagen AG do
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– To release pressure,d bwrapyV
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Danger of fire caused by escaping fuel

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When the battery is connected and the driver door opens, the door
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contact switch activates the fuel pump. Escaping fuel can ignite
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and cause a fire.

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– Disconnect voltage supply to fuel pump before opening the

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Observe the fill level of the fuel tank:

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♦ Fuel tank must be only partly filled. To find out how much fuel
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♦ If necessary, drain fuel tank

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⇒ “2.2 Emptying fuel tank”, page 17 .

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♦ Before starting work, the extraction hose of a switched-on ex‐
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haust gas extraction system must be laid near to the assembly
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♦ The exhaust extraction system is used to extract fuel vapours.
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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.
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
1. Safety information 1
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
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♦ Wash the engine onlys auwith the ignition switched off. or
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♦ Entries are stored in the event memory of the engine control
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⇒ Vehicle diagnostic tester.
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1.2 Safety measures when working on vehicles with a start/stop system
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Risk of injury due to unexpected motor start
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If the vehicle's start/stop system is activated, the engine can start
unexpectedly. A message in the dash panel insert indicates
whether the Start/Stop system is activated.
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– Deactivate Start/Stop system by switching off the ignition.
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1.3 Safety precautions when using testers and measuring instruments during
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Risk of injury caused by unsecured testing and measuring instru‐

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When the front passenger airbag is triggered in an accident, in‐
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– 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 the

SCR system
When removing and installing components of the SCR system,
note the following:
♦ The tank for reducing agent must be empty when working on
the SCR system. Information on when the tank for reducing
agent has to be emptied can be obtained from the respective
work instruction. Drain tank for reducing agent ⇒ Rep. gr. 26 ;
SCR system (selective catalytic reduction) .
Automatic return of reducing agent
• After the ignition has been switched off, the reducing agent is
returned from the metering line leading to the reducing agent
injector - N474- back to the reducing agent tank.
• Before any work is done in this area, it is necessary to wait
until all the reducing agent has been returned to the tank; this
can take up to 10 minutes after the ignition is switched off.
• Similarly, it is not permissible to disconnect the battery until all
the reducing agent has been returned to the tank, i.e. 10 mi‐
2 Rep. gr.00 - Technical data

nutes after the ignition is switched off ⇒ Electrical system;

Rep. gr. 27 ; Battery; Disconnecting and connecting battery .
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1. Safety information 3
2 Identification
⇒ “2.1 Engine number/engine data”, page 4
2.1 Engine number/engine data

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Identification code CAYC CFFA CFFB
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Exhaust emission standard EU 5 EU 5 thor EU 5 EU 5 EU 5 EU
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Displace‐ l 1.6 2.0 ss 2.0 2.0 2.0 2.0c
ment
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Power kW 77 100 103 125 130 125
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Fuel: acc. to DIN EN 590 DIN EN 590 DIN EN 590 DIN EN 590 DIN EN 590
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1) only for India, South America and Russia
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Identification code CUVC CUWA
Exhaust emission standard EU 6 EU 6
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Displacement l 2.0 2.0
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Power kW 110 135

RON DIN EN 590 DIN EN 590
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3 General information
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3.1 Rules for
s cleanliness when working on
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auxiliary/supplementary heater and fuel
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When working on the fuel supply and injection system, pay careful
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attention to the following “rules”:
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♦ Thoroughly clean all joints and surrounding areas before dis‐
mantling.
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♦ Place removed parts on a clean surface and cover them over.
Use lint-free cloths only.
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♦ Carefully cover opened components or seal them if repairs
cannot be carried out immediately.
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♦ Install only clean parts; do not remove new parts from pack‐
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aging until immediately before installing. Do not use parts that
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have been kept unpackaged (for example in toolboxes).
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♦ When the system is open: Do not work with compressed air.
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♦ Do not move the vehicle.
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♦ Immediately seal open lines and unions with clean plugs, for
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example from engine bung set - VAS 6122- .

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♦ Protect disconnected electrical connectors from dirt and water,
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3. General information 5
4 Repair notes
⇒ “4.1 Pipe/wire routing and attachment”, page 6
⇒ “4.2 General repair instructions”, page 6
4.1 Pipe/wire routing and attachment

Risk of damage to lines
Lines may become damaged by moving or hot components.
– Route lines in their original positions.
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– Make sure there is sufficientoclearance
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♦ Mark components prior to removal to prevent them from being
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interchanged and to ensure that they are fitted in their original
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installation positions. Where necessary, make sketches or
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4.2 General repair instructions
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Before starting work on the fuel supply system, the following steps
must be performed:
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♦ 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. ss o
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♦ It is used to extract fuel fumes.

f inform
mer
♦ If no exhaust gas extraction system is available, a radial fan

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with a displacement greater than 15 m3/h can be used provid‐

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ing that motor is not in air flow.

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

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♦ Interrupt power supply to fuel system pressurisation pump -

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G6- ⇒ Current flow diagrams, Electrical fault finding and Fitting

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♦ Drain fuel tank ⇒ page 17 . co Vo
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20 – Fuel supply system

1 Procedure should vehicle be misfu‐
eled
Irreversible damage to high-pressure components, especially the
high-pressure pump, can occur due to lack of lubrication through
diesel when filling the fuel tank with incorrect 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. Test sample, if unsure of fuel quality. Analyse fuel using Volkswagen AG
Fuel analyser unit - VAS 6774- ⇒ Instruction manual . This ana‐swagen AG. does
lyser unit is no substitute for a laboratory test in warranty cases.
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Special tools and workshop equipment required oris tee
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♦ Fuel identification unit - VAS 6774- ss
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These instructions are intended as a guide through the individual
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work steps by means of a flowchart, with various factors being

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Was the engine started with the incorrect fuel?
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⇒ “1.1 Step 1, engine was started with incorrect fuel”, pyri by
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No
⇒ “1.2 Step 2, engine was not started with incorrect fuel”, page
9
1.1 Step 1, engine was started with incorrect

fuel
Special tools and workshop equipment required
1. Procedure should vehicle be misfueled 7

♦ Pressure gauge - VAS 6551-
VAS 6551
I N20-1 07 10 I
♦ Adapter set - VAS 6551/5-

VAS 6551/5
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♦ Removal wedge - 3409-

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♦ Vehicle diagnosis and service information system

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– Empty fuel tank as far as possible via fuel filler neck using fuel
h re
extractor - VAS 5190- ⇒ page 17 .

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– Remove rear bench seat ⇒ General body repairs, interior;

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

individual seats .
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– Unclip cover -1- for flange at retaining tabs -arrows-, using re‐
moval wedge - 3409- .
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NOTICE
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The fuel pump is activated when opening a door when the bat‐
orm
tery is connected! Fuel can escape if the system has been

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8 Rep. gr.20 - Fuel supply system

– Pull fuel return line (blue line or blue marking) -1- off fuel de‐
livery unit. Separate plug-in connectors ⇒ page 46 .
– Connect pressure gauge pipe -VAS 6551/5-2- to the fuel re‐
turn line -1-.
– Put open end of line -VAS 6551/5-2- into a suitable container.
– Connect vehicle diagnostic tester and then carry out guided
function “Fuel pump activation (Emptying fuel system)”.
– Carry out the guided function Empty fuel tank .
I N20-1 078 1 I
Note
The fuel pump is now activated.
– Repeat procedure, if necessary, until fuel tank is completely

empty.
Remove fuel delivery unit ⇒ page 37 .
– Check fuel tank for metal particles.
– Drain fuel pump reservoir of fuel delivery unit.
– Carry out a visual inspection for foreign bodies and metal par‐
ticles in fuel pump reservoir and on preliminary filter.
Metal particles found?
Yes
⇒ “1.3 Step 3, there are metal particles in fuel delivery unit and
fuel tank”, page 11
No
⇒ “1.4 Step 4, there are no metal particles in fuel delivery unit
or fuel tank”, page 12 olks
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1.2 Step 2, engine was not started with in‐
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I W00-1 087 4 I
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VAS 6551/5
...,_ -1
-2
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I W00-11272 I
♦ Hose clamp pliers - V.A.G 1921-

V.A.G 1921
I W00-11169 I

3409
AG. Volkswagen AG d
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– Empty fuel tank as far as possible via fuel filler neck using fuel
, is n
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extractor - VAS 5190- ⇒ page 17 .

hole
spec

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individual seats .
rrectness of i

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NOTICE
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Rep. gr.20 - Fuel supply system
wage e
– Pull fuel return lineyV
o(blue
lks line or blue marking) s-1-
not off fuel de‐
gu
livery unit. Separate
ised b plug-in connectors ⇒ page 46 . aran
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– Connects pressure
au gauge pipe -VAS 6551/5-2- to the fuel ore‐
ra
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turn line -1-.
s
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– Put open end of line -VAS 6551/5-2- into a suitable container.
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– Connect vehicle diagnostic tester and then carry out guided
ility
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I N20-1 078 1 I
Note
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– Repeat procedure, if necessary, until fuel tank is completely

empty.
nf
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– Fill fuel tank with 5 litres of diesel fuel.
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– Completely empty fuel tank again as described above.
om
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– Reconnect fuel return line (blue or blue marking) -1-.

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– Renew fuel filter ⇒ page 52 .
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– Fill up vehicle and perform road test.
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1.3 Step 3, there are metal particles in fuel

delivery unit and fuel tank
♦ Diesel extractor - VAS 5226-
VAS 5226
I W00-11 87 1
– Clean fuel delivery unit and fuel tank with diesel extractor -
VAS 5226- .
Install fuel delivery unit ⇒ page 37 .
For vehicles with auxiliary heating
– Check fuel line between fuel tank and metering pump - V54-
for metal particles. If required, renew both ⇒ Auxiliary heater,

supplementary heater; Rep. gr. 82 ; Fuel supply system; Re‐

moving and installing metering pump - V54- .
Continued for all vehicles:
– 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 (fuel rail):
Removing and installing high-pressure lines .
♦ Fuel rail including fuel pressure regulating valve - N 276- and
fuel pressure sender - G 247- ⇒ Rep. gr. 23 ; Injectors/fuel
rail; Removing and installing fuel rail
n AG . Volkswagen AG
♦ Injector ⇒ Rep. gr. 23 ; Injectors/fuel rail (fuel rail): Removingwage does
and installing injectors . Volks not
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♦ Fuel return lines (leakage oil lines) ⇒ Rep. gr.
ut
ho23 ; Injection
r eo
system; Assembly overview - fuel system ss a ra
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♦ Fuel filter
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⇒ “5.2 Removing and installing fuel filter”, page 52
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– Fill up vehicle.
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– Bleed fuel system ⇒ Rep. gr. 23 ; Injection system; Filling/
h re
bleeding fuel system .
hole
spec
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– Carry out road test.
t to the co
End
1.4 Step 4, there are no metal particles in
rrectness of i
fuel delivery unit or fuel tank
l purpos
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CD NOTICE ion
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When the fuel metering valve - N290- is removed, there is the

at
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risk of damage to the high-pressure pump by the ingress of dirt

p
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from the outside. Scrupulous cleanliness must therefore be en‐

f
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– Carefully clean high-pressure pump in vicinity of fuel metering
py by
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valve - N290- . Prote
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– Detach connector from valve.

Vehicles with radiator, variant 1
– Unscrew bolts -arrows-, and carefully remove fuel metering
valve - N290- -A-.
– Check fuel metering valve - N290- and high-pressure pump
for metal particles.

Vehicles with radiator, variant 2

– Unscrew bolts -arrows-, and carefully remove fuel metering
valve - N290- -A-.
– Check fuel metering valve - N290- and high-pressure pump
for metal particles. en AG. V
olkswagen AG
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Metal particles found? olks not
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⇒ “1.5 Step 5, there are smetal
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⇒ “1.6 Step 6, there are no metal particles in high-pressure
erm
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pump”, page 13
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1.5 Step 5, there are metal particles in high-
hole
spec
pressure pump
es, in part or in w
t to the co
– Renew following high-pressure components:
♦ High-pressure lines ⇒ Rep. gr. 23 ; Injectors/fuel rail (fuel rail):
rrectness of i
Removing and installing high-pressure lines .
l purpos
♦ Fuel rail including fuel pressure regulating valve - N 276- and

fuel pressure sender - G 247- ⇒ Rep. gr. 23 ; Injectors/fuel
nf
ercia
rail; Removing and installing fuel rail
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♦ Injector ⇒ Rep. gr. 23 ; Injectors/fuel rail (fuel rail): Removing
om
and installing injectors .
n in
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♦ Fuel return lines (leakage oil lines) ⇒ Rep. gr. 23 ; Injection

t
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system; Assembly overview - fuel system

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⇒ “5.2 Removing and installing fuel filter”, page 52 . Cop py
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rig ht
– Fill up vehicle. py by
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– Bleed fuel system ⇒ Rep. gr. 23 ; Injection system; Filling/ Prote AG.
– Carry out road test.
End
1.6 Step 6, there are no metal particles in

high-pressure pump
– Renew fuel filter ⇒ page 52 .
– Bleed fuel system ⇒ Rep. gr. 23 ; Injection system; Filling/
– Fill up vehicle and perform road test.
End

2 Fuel
⇒ “2.1 Assembly overview - fuel tank”, page 14
⇒ “2.2 Emptying fuel tank”, page 17
⇒ “2.3 Removing and installing fuel tank”, page 25
2.1 Assembly overview - fuel tank

⇒ “2.1.1 Assembly overview - fuel tank, vehicles with front-wheel
drive”, page 14
⇒ “2.1.2 Assembly overview - fuel tank, vehicles with four-wheel
drive”, page 16 AG. Volkswagen
agen AG do
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2.1.1 Assembly
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vehicles
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1 - Cap ss c
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2 - Bolt
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❑ 1.5 Nm
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3 - Tank flap unit -----4

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❑ With rubber cup. /
hole
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❑ Removing and installing spec .i
es, in part or in w
⇒ General body repairs, t to the co

• /,·-/-----.
~ ------ 5
exterior; Rep. gr. 55 ; 'y'!
Tank flap unit; Remov‐ ,'J
I
ing and installing fuel
rrectness of i
tank flap unit . ---------e

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4 - Earth connection
❑ Ensure firm seating. ,---7
nform
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5 - Angled piece
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6 - Bolt
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❑ 8 Nm +90°
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---9
❑ Removing and installing
⇒ page 25 8
❑ Emptying fuel tank
⇒ page 17 .
9 '
8 - Tensioning straps
❑ Observe installation po‐ 10 - ---
sition
❑ Use suitable workshop
equipment to prevent
the securing straps from
turning while tightening the bolts.
9 - Bolt
❑ 20 Nm +90°
10 - Clamping washer
❑ 2.5 Nm

11 - Heat shield
❑ For fuel tank
12 - Metering pump - V54-
❑ Vehicles with auxiliary heater
❑ Removing and installing ⇒ Auxiliary heater, supplementary heater; Rep. gr. 82 ; Fuel supply system;
Removing and installing metering pump - V54- .
Installation position of fuel delivery unit 5 ~

Marking -4- on flange points opposite direction of travel.
Note 3
. . ~
The fuel delivery unit flange can only be installed in this position.
1-
2-
Black supply line with arrow to union on flange
Blue return line (or with blue marking) to connection marked
~ ~
“R”
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3- Supply line
Vol
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After installing fuel delivery unit flange, check that fuel lines are
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still clipped onto fuel tank.

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2. Fuel 15
2.1.2 Assembly overview - fuel tank, vehicles with four-wheel drive
1 - Supply line
❑ Clipped onto fuel tank
❑ Ensure firm seating.
2 - Locking ring
❑ Remove and install us‐
ing wrench - T10202- .
❑ Tightening torque
110 Nm
3 - Cap
❑ Renew if damaged
4 - Securing bolt
❑ 1.5 Nm
5 - Tank flap unit
❑ With rubber cup.
⇒ General body repairs,
exterior; Rep. gr. 55 ;
Tank flap unit; Remov‐
ing and installing fuel
tank flap unit .
6 - Bolt
❑ 8 Nm +90° agen
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❑ Ensure firm seating. utho eo
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8 - Pressure retention valve
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with connecting hose

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❑ To remove, grasp se‐

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curing ring (grey) and

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9 - Breather line
es, in part or in w
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10 - Suction-jet pump
❑ Clipped onto fuel gauge sender 2 - G169-
l purpos
❑ Removing and installing ⇒ page 91

nf
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11 - Bolt
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❑ 20 Nm +90°
or c
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12 - Seal
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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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13 - Fuel gauge sender 2 - G169-
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❑ Note installation position on fuel tank ⇒ page 17

14 - Fuel
❑ Emptying ⇒ page 17
15 - Heat shield
❑ Bolted with clamping washers.
16 - Bolt
❑ 20 Nm +90°
17 - Tensioning straps
❑ Observe installation position
❑ Use suitable workshop equipment to prevent the securing straps from turning while tightening the bolts.
18 - Breather line
19 - Fuel delivery unit
❑ With fuel gauge sender - G-
❑ Removing and installing fuel gauge sender
agen - G- ⇒ pageA42
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20 - Flange with fuel filter tho or
au ac
❑ With 6 bar pressure relief
ss valve
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❑ Note installation position on fuel tank ⇒ page 17
pt
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❑ removing and installing
erm
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Installation position of flange for fuel delivery unit and fuel gauge
hole
A B
spec
sender 2 - G169-
es, in part or in w
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The marking on the flange must align with the marking on the fuel
tank -arrow-.
rrectness of i
Note
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The marking on the fuel tank is not clearly visible.

nform
ercia
A - Flange for fuel delivery unit

m
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B - Flange for fuel gauge sender 2 - G169-

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2.2 Emptying fuel tank

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⇒ “2.2.1 Emptying fuel tank when fuel pump is intact”,
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page 17
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⇒ “2.2.2 Emptying fuel tank if it is more than 3/4 full”, page 19
cop Vo
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⇒ “2.2.3 Emptying fuel tank with fuel tank less than 3/4 full, vehi‐
cles with front-wheel drive”, page 20
⇒ “2.2.4 Emptying fuel tank with fuel tank less than 3/4 full, vehi‐
cles with four-wheel drive”, page 21
2.2.1 Emptying fuel tank when fuel pump is

intact
2. Fuel 17
AG. Volkswagen AG d
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CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤d by V gu
ara
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♦ Fuel extractor - VAS 5190-
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VAS 5190
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I W00-11291 I
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♦ Adapter for fuel extraction - VAS 5190-
nform
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VAS 5190/1-3
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tion in
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I W00-11248 I
Note 1
If the fuel extraction unit - VAS 5190- is still fitted with the extrac‐
tion hose with a solid tip, the extraction hose must be replaced VAS 5190
with the version with a screwed tip.
– Unscrew tip -1- from extraction hose of fuel extraction unit -

\
VAS 5190/1
VAS 5190- . VAS 5190/2
– Screw fuel extraction adapter - VAS 5190 /2- from fuel extrac‐ VAS 5190/3
tion adapter set - VAS 5190 /10- onto extraction hose. I A20-1 0555 I
– Pull off supply line -B-, and catch escaping fuel with a cloth.
Separate plug-in connectors ⇒ page 46 .

– Connect fuel extractor - VAS 5190- with adapter for fuel ex‐
tractor - VAS 5190 /3 - to fuel supply line.
A CAUTION
Risk of fire due to escaping fuel.
Risk of severe injuries and burns.
– Check all connected lines for secure fit by pulling.
– Take any fuel-soaked cloths away from area of vehicle.
– Connect the vehicle diagnostic tester .

– Repeat the function if necessary. agen
AG. Volkswagen AG d
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[I] Note
s aut
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– Open shut-off tap on fuel extractor - VAS 5190- until fuel tank
erm
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is emptied.
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2.2.2 Emptying fuel tank if it is more than 3/4
hole
spec
es, in part or in w
full
t to the co
rrectness of i
VAS 5190
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♦ Fuel extractor - VAS 5190 A- for E 85 fuel (not shown). cted agen
Prote AG.
– Secure earth wire of fuel extractor to a bare metal part of the

body.
– Make a mark -arrow- on the hose with insulating tape at a dis‐
tance = 950 mm from end of extraction hose.
[I] Note
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. You
must therefore push hose into filler neck only as far as marking.
– Push extraction hose into fuel tank until marking on hose co‐
incides with filler neck.
– Drain fuel tank via filler neck as far as possible.
– Pull extraction hose out carefully.
2. Fuel 19
[I] Note
♦ When no more fuel is extracted, the tank is emptied just

enough for the sender flange to be opened without danger.
The tank may be removed while containing remaining fuel.
♦ Draining fuel tank completely ⇒ page 20
2.2.3 Emptying fuel tank with fuel tank less than 3/4 full, vehicles with front-wheel
drive
Special tools and workshop

equipment required Tl 0202 VAG 1332
.:..:.-r
I 7
'v'.A.S 5190
-. , -
AG. Volkswagen AG d
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IW20-10028 I
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♦ Special wrench - T10202-

nform
ercia
♦ Torque wrench - V.A.G 1332-

m
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tio

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

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72 ; Rear seats; Removing and installing bench seat/individual Cop py
seats .
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– Remove cover of fuel delivery unit.

– Release connector -4- and fuel line -1- and pull them off flange
-3-. Separate plug-in connectors ⇒ page 46 .
– If fitted, pull out supply line -2- to metering pump - V54- . Sep‐
arate plug-in connectors ⇒ page 46 .
– Open locking ring using wrench - T10202- .

– Do not cant key - T10202- and press against locking ring firmly.
If the key slips off, the fuel delivery unit can be damaged.
– Raise sender flange.
– Insert suction hose of fuel extractor - VAS 5190- as far as n AG. Volkswagen AG do
possible into fuel tank. Then extract fuel. lkswage es n
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byV ua
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If fuel tank was only emptied, install sender flange again or is tee
h
⇒ page 37 . aut or
ac
ss
Torque settings
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un
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an
d
♦ ⇒ “2.1.2 Assembly overview - fuel tank, vehicles with four-

itte
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erm
wheel drive”, page 16
ab
ility
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♦ ⇒ General body repairs, interior; Rep. gr. 72 ; Rear seat;
wit
is n
Removing and installing bench seat / individual seats
h re
ole,
spec
♦ ⇒ Auxiliary heater; Rep. gr. 82 ; Fuel supply system; Overview

of fitting locations – fuel supply system .
t to the co
2.2.4 Emptying fuel tank with fuel tank less than 3/4 full, vehicles with four-wheel
rrectne
drive
ss o
cial p
f inform
mer
atio
om
n
c
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Cop py
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2. Fuel 21

AG. Volkswagen AG d
equipment required 3409
agen
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es, in part or in w
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V.A.G 1332 VAS 5190
rrectness of i
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nform
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at
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c
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Prote AG.
I1N3J- 10054 I

[I) Note
To drain fuel tank completely: fuel must be extracted from fuel

delivery unit flange and also from fuel pump sender 2 - G169-
flange.

body.
Draining fuel tank at fuel delivery unit flange ⇒ page 22 .
Draining fuel tank at fuel gauge sender 2 - G169- flange
⇒ page 24 .
Emptying fuel tank at fuel delivery unit flange
– Remove bench seat or fold it upwards ⇒ General body repairs,
interior; Rep. gr. 72 ; Rear seat; Removing and installing
bench seat / individual seats .

– Guide carpet out and fold upwards, if fitted.

– Remove right cover with fuel pump control unit - J538- -2- from
assembly opening above fuel delivery unit.
– To do this, unclip right cover -1- at retaining tabs -arrows- using

removal wedge - 3409- . agen
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es, in part or in w
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Vehicles with auxiliary heater
– Remove connector -1- from cover -3-.
rrectness of i
– Release connectors -1- and pull off.
l purpos
– Unclip sealing grommet -2- downwards from cover -3-.

– Guide wiring harness out downwards.
nform
mercia
at
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ion
c
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or
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do
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– Release and pull fuel delivery line -2- from flange -1-. Separate
Co
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plug-in connectors ⇒ page 46 .
t. C rig
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2. Fuel 23

– Pull connector -1- off flange -3-.
– Disconnect fuel line -2- at flange -3-. Separate plug-in con‐
nectors ⇒ page 46 .
AG. Volkswagen AG d
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olksw not
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– Open locking ring using wrench - T10202- . ss c
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itte
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erm
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ility
– Raise flange.
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– Insert extraction hose of fuel extractor - VAS 5190- as far as
h re
hole
possible into fuel tank. .
spec
es, in part or in w
– Then extract fuel.
t to the co
– Draining fuel tank at flange of fuel gauge sender 2 - G169-
⇒ page 24 .
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Draining fuel tank at fuel gauge sender 2 - G169- flange
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– Insert extraction hose of fuel extractor - VAS 5190- as far as
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spec
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2.3 Removing and installing fuel tank
⇒ “2.3.1 Removing and installing fuel tank - vehicles with front-
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⇒ “2.3.2 Removing and installing fuel tank - vehicles with four-

nform
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2.3.1 Removing and installing fuel tank - ve‐

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hicles with front-wheel drive
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I W00-11166 I

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2. Fuel 25
♦ Engine and gearbox jack - V.A.G 1383 A-

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seats .
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– Remove fuel delivery unit.

– Pull 5-pin connector -5- off fuel delivery unit flange.
rrectne
– Remove tank flap unit -2- ⇒ General body repairs, exterior;

s
Rep. gr. 55 ; Tank flap unit; Removing and installing tank flap
s o
unit .
cial p
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– Drain fuel tank ⇒ page 17 .

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– Unclip line from filler neck -arrows-.

– Remove underbody panel between rear axle and side under‐
body panels ⇒ General body repairs, exterior; Rep. gr. 66 ;
Underbody panel; Removing and installing underbody panels .
– Remove rear axle panel ⇒ Running gear, axles, steering; Rep.
gr. 42 ; Rear axle; Lowering rear axle .
1 1,120 -10194 1
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2. Fuel 27
– Loosen securing bolts -arrows-, and lower rear axle ⇒ Run‐

ning gear, axles, steering; Rep. gr. 42 ; Rear axle; Lowering
rear axle .
– Place engine and gearbox jack - V.A.G 1383 A- under fuel tank
to support it.
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spec
es, in part or in w
– Use suitable workshop equipment to prevent the securing
t to the co
straps from turning while tightening the bolts.
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tened to bracket. rrectness of i
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into the opening in the body.
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– Fill fuel tank with at least 5 litres of fuel.
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CD NOTICE
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Risk of irreparable damage to fuel pump if allowed to run dry.

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at
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om
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♦ ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Assembly overview

at
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cted AG.
agen
♦ ⇒ Running gear, axles, steering; Rep. gr. 44 ; Wheels, tyres;

Wheel change .
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liner; Assembly overview- rear wheel housing liner .
2.3.2 Removing and installing fuel tank - ve‐

hicles with four-wheel drive
V.A.G 1331
-
I W00-11166 I
2. Fuel 29

3409
I W00-11118 I
♦ Engine and gearbox jack - V.A.G 1383 A-

V.A.G 1383 A
I W00-11135 I

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Drain fuel tank with fuel extractor - VAS 5190- ⇒ page 17 .

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

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Rep. gr. 44 ; Wheels, tyres and alignment .

nform
mer
– Remove rear right wheel housing liner ⇒ General body re‐

atio
m
pairs, exterior; Rep. gr. 66 ; Wheel housing liner; Assembly

o
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overview - rear wheel housing liner .

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– Remove tank flap unit -2- ⇒ General body repairs, exterior;

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– Remove cover, and disconnect connector -arrow-.
Note
For vehicles with auxiliary heater the metering pump - V54- con‐
nector must be separated additionally.
– Disconnect connector for all-wheel drive control unit - J492-

-arrow- on left side.
– Unclip sealing grommet -1- downwards from cover. Guide wir‐
ing harness of all-wheel drive control unit - J492- out down‐
wards.
~
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flange when doing this. ~ 1
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– Unbolt filler neck from body -arrows-.

– Remove front left and right underbody panels from underbody.
– Remove rear part of exhaust system ⇒ Rep. gr. 26 ; Exhaust
system/silencer; Assembly overview - silencers .
– Detach return line -1- and supply line -2- at connections. Sep‐
arate plug-in connectors ⇒ page 46 .
– If fitted, detach fuel line -3- for metering pump - V54- at con‐
nection ⇒ page 46 .
– Remove tunnel cross-piece from underbody -arrows-.

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installing propshaft . ss au ra
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– Remove heat shield under fuel tank.

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– Lower rear axle ⇒ Running gear, axles, steering; Rep. gr. 42 ;

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Rear axle; Lowering rear axle .

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– Place engine and gearbox jack - V.A.G 1383 A- under fuel tank
to support it.
– Unbolt securing straps with securing bolts -arrows-.
– With the aid of a 2nd mechanic, guide out filler neck from be‐
tween rear axle and body. Then, place fuel tank on engine and
gearbox jack - V.A.G 1383 A- .
– If necessary, unclip lines secured to upper side of fuel tank.
Installing
– Clip in line from the four-wheel drive control unit - J492- at the
fuel tank -arrow- if necessary.
– Guide filler neck in between rear axle and body.
– If metering pump - V54- is fitted, ensure that it is securely fas‐
tened to bracket. G. Volkswagen nA AG do
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ole,
spec
Rep. gr. 26 ; Exhaust pipes/silencers; Assembly overview -
silencers .
t to the co
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– Ensure that line connections are tight.

– Ensure connections are secured properly by pulling.
ss o
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2. Fuel 33
– Check whether there are signs of oxidation on the earth wire

of the connectors, remove if necessary.
– Check installation position of earth connection.
• Ensure that connector -2- is seated securely on metal ring
-3-.
• Contact -1- must be attached to fuel tank -4- and secured with
spacer bush -5-.
– Check connection of metal ring on fuel filler neck by measuring
between ring and a bare metal part of body using an ohmme‐
ter.
• Specification: approx. 0 ohm.
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gen AG does
• If the specification is not attained, there is a risk of explosion
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– Fill fuel tank with at least 5 litres of fuel. utho eo
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CD NOTICE
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Risk of irreparable damage to fuel pump if allowed to run dry.
erm
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– Never allow fuel pump to run »dry«.
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spec
– Fit adapter cable onto all-wheel drive control unit - J492- .
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Torque settings II ' LJ [l
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rrectne
♦ ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Assembly overview
s
- silencers
s o
cial p
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nform
mer
atio
m
♦ ⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit;

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i
Removing and installing tank flap unit
or
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'=a- I N20-10146 I
thi
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♦ ⇒ Running gear, axles, steering; Rep. gr. 44 ; Wheels, tyres;

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Wheel change .
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t.
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♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
Co
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liner; Assembly overview- rear wheel housing liner .
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3 Fuel delivery unit, fuel gauge sender

⇒ “3.1 Assembly overview - fuel delivery unit/fuel gauge sender”,
page 35
⇒ “3.2 Removing and installing fuel delivery unit, fuel gauge send‐
er”, page 37
⇒ “3.3 Removing and installing fuel gauge sender G ”,
page 42
⇒ “3.4 Removing and installing fuel gauge sender 2 G169 ”, page
43
3.1 Assembly overview - fuel delivery unit/

fuel gauge sender
⇒ “3.1.1 Assembly overview - fuel delivery unit/fuel gauge send‐
er”, page 35
⇒ “3.1.2 Assembly overview - fuel delivery unit/fuel gauge sender,
vehicles with auxiliary heater”, page 37
3.1.1 Assembly overview - fuel delivery unit/fuel gauge sender
1 - Locking ring
❑ Remove and install us‐
ing wrench - 3087- . A#::____ _ _ 1
❑ 110 Nm
2 - Supply line to fuel filter agen
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❑ For fuel delivery unit.
3. Fuel delivery unit, fuel gauge sender 35

❑ Note installation position of flange on fuel tank ⇒ page 36 .
⇒ “3.2 Removing and installing fuel delivery unit, fuel gauge sender”, page 37
❑ With fuel system pressurisation pump - G6- and fuel gauge sender.
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8 - Fuel gauge sender (G).
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❑ Removing and installing fuel gauge sender ⇒ page 42 .
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The marking on the fuel tank is not clearly visible. It is opposite
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A - Flange for fuel delivery unit.
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B - Fuel gauge sender 2 - G169- flange (only vehicles with four-

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3.1.2 Assembly overview - fuel delivery unit/fuel gauge sender, vehicles with
auxiliary heater

❑ With fuel system pres‐
surisation pump - G6-
❑ With integrated fuel fil‐
ter; fuel filter cannot be
renewed separately
❑ Carrying out electrical
test of fuel pump in Gui-
ded fault finding 4-
mode ⇒ Vehicle diag‐
nostic tester 3-
⇒ page 40
❑ After installing, fill vehi‐
cle with at least 5 litres
of fuel.
2-~i
, I
2 - Clip 1
❑ Secure hose connection
with the hose clips cor‐
responding to original
equipment.
3 - Clip
❑ Secure hose connection
with the hose clips cor‐
responding to original
equipment.
4 - Fuel line AG. Volkswagen AG d
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3.2 Removing and installing fuel delivery

unit, fuel gauge sender
rrectne
⇒ “3.2.1 Removing and installing fuel delivery unit, fuel gauge

ss
sender”, page 37
o
cial p
f in
⇒ “3.2.2 Removing and installing fuel line for auxiliary/supple‐

form
mer
mentary heater”, page 40

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3.2.1 Removing and installing fuel delivery

n
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unit, fuel gauge sender

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3. Fuel delivery unit, fuel gauge sender

T10202
I W00-11313 I

V.A.G 1332
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I W00-11118 I
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• The fuel tank must not be more than 3/4 full. This ensures that
atio
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the fill level is below the flange of the fuel delivery unit.
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– First check that connector -arrow- is fitted securely by pulling

connector without pressing catch. If connector was not inser‐
ted correctly, repeat function test.
– First press down connector -arrow-.
– Then pull locking element of connector upwards. At same
time, remove connector upwards.
– Unlock and pull fuel line -1- and -3- off flange. Separate plug-
in connectors ⇒ page 46 .
AG. Volkswagen AG d
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– Press securing ring and pull fuel line -A- for suction-jet pump
off.
– Press tab -B- of suction-jet pump in -direction of arrow- and
unclip from fuel delivery unit.
– Carefully lift flange of fuel delivery unit.
– Lift delivery unit slightly, and remove seal from opening in fuel
tank.
– When the delivery unit is replaced, the old delivery unit must
emptied before disposal.
• Observe relevant disposal regulations.
Installing
– Renew seal.

– Insert dry seal -1- for fuel delivery unit into opening in fuel tank.
– When inserting fuel delivery unit, ensure that fuel gauge send‐
er is not bent.
– Coat inner side of seal -1- with fuel.
– Press down sealing flange -2- against spring force.
– Bring sealing flange to installation position.
– When flange is inserted, ensure that seal is not damaged or
squashed.
– Installing the fuel delivery unit is carried out in reverse order I A20-10 98 7 I
of removal.
– Push fuel lines -1- and -2- onto flange until they engage audi‐
bly.
– Note installation position of flanges -arrows-:

• Tab -2- on flange must be between lugs -1- and -3- on fuel
tank.
• -Arrow- points in direction of travel.
A - Flange for fuel delivery unit
B - Flange for fuel gauge sender 2 - G169-
– Tighten locking ring using wrench - T10202- .
– Note installation position of covers -arrows-: A B

The -arrows- on the covers point forwards.
wage es n
A - Cover for fuel delivery unit yV
olks ot g
ua
d b ran
B - Cover for fuel gauge sender 2 - G169- ir se tee
tho
u or
a ac
Torque settings ss
ce
e
nl
pt
♦ ⇒ “3.1 Assembly overview - fuel delivery unit/fuel gauge send‐
du
an
itte
er”, page 35
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ab
ility
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I N2 0- 1 022 6 I
h re
hole
spec
3.2.2 Removing and installing fuel line for aux‐
es, in part or in w
t to the co
iliary/supplementary heater
Removing
rrectness of i
– The fuel tank must not be more than 3/4 full. This ensures that
l purpos
the fill level is below the flange of the fuel delivery unit.
nform
ercia

m

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io

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individual seats .
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ate
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– Unclip sealing grommet -1- downwards from cover -2-.
• 0
– Push cover -2- back along wiring harness -3-.

– Release and pull off connector -1- on sealing flange.
– If fitted, detach connector AG-2-
. Vofor
lkswmetering
agen AG pump - V54- of aux‐
agen does
iliary heater onVosealing
lksw flange and lay connectornot aside.
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If fuel line for metering pump - V54- is to be disconnected from

spec
fuel delivery unit:

t to the co
– Open lower clip -3- on flange -1-.
A CAUTION
rrectne
The fuel system is pressurised.

ss
Danger of injury through fuel spray.

o
cial p
f i

nform
mer
– Wear protective gloves.

atio
m
– To release pressure, wrap a clean cloth around the connec‐

o
n
c
i
or
tion and carefully loosen the connection.

thi
te
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– Do not open upper clip -4-.

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– Pull fuel line -2- together with grommet off flange.
Co
Cop py
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If a new fuel delivery unit is installed:
yri
p by
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cted
– Remove fuel line ⇒ page 41 .
agen
Prote AG.

– Remove fuel delivery unit ⇒ page 37 .

– The connection on the fuel delivery unit -2- must be opened.
– To do this, cut off sealing piece -3- on connection -1-.
– Cut it off on the respective marking line -arrow-.
– Deburr edges of cutting point.
– Prevent any dirt or swarf from entering the fuel delivery unit.
– Check fuel delivery unit for soiling, and clean it as necessary.
– Install fuel delivery unit ⇒ page 37 . n AG. Volkswagen AG do
lkswage es n
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Installing fuel line: tho tee
or
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s
– Insert fuel line -3- in connection -5-.
s
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un
pt
-2
– Insert fuel line to stop -arrow-.
an
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itte
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ab
– While doing this, fit grommet -1- over connection.
ility
-3
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– Renew lower clip -4-.
wit
is n
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ole,
– If the fuel line or grommet has been renewed, the upper clip
spec
must be renewed as well.
t to the co
– Renew clips -2- and -4-, if they have been opened.
– Secure hose connections with hose clips corresponding to
rrectne
original equipment.
Torque settings
ss o
cial p
♦ ⇒ “3.1.2 Assembly overview - fuel delivery unit/fuel gauge
f in
sender, vehicles with auxiliary heater”, page 37
form
mer
atio
m
3.3 Removing and installing fuel gauge

o
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sender - G-
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Removing
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– Remove fuel delivery unit ⇒ page 37 . t. Cop py
rig
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– Press together securing tabs -arrows- and remove fuel gauge yri
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sender - G- upwards.
c by lksw
cted agen
Prote AG.
– Note colour assignment of cables for reinstallation.

– Release and pull off connectors -1 … 3-. Then bend back

locking lugs of connectors.
Installing
I A2 0-1 0431 I
– Connect connectors -1 … 3-. Adhere to colour assignment

while doing this.
– Check connectors are secured properly by pulling.
– Insert fuel gauge sender - G- into guide on fuel delivery unit
and press down until it engages.
– Clip lines on corresponding positions and secure on cup into
retaining slots.
– Install fuel delivery unit ⇒ page 37 .
I A20-1 0431 I
3.4 Removing and installing fuel gauge

sender 2 - G169-
en AG. V
olkswagen AG
ag does
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♦ Special wrench - T10202- y Vol gu
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ed nte
T10202
oris eo
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pt
du
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spec
es, in part or in w
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I W00-11313 I
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V.A.G 1332
nf
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orm
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ht I W00-11165 I
pyri by
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Prote AG.


3409
AG. Volkswagen AG d
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I W00-11118 I
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Removing
, is n
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• The fuel tank must not be more than 1/2 full.
spec
es, in part or in w
t to the co
– Drain fuel tank, if necessary, using fuel extractor - VAS 5190-
⇒ page 17 .
rrectness of i
72 ; Rear seat; Removing and installing bench seat / individual
l purpos
seats .
– Disconnect connector for all-wheel drive control unit - J492-
nform
ercia
-arrow-.
m
– Unclip sealing grommet -1- downwards from cover. Guide wir‐
a
com
tio
ing harness of all-wheel drive control unit - J492- out down‐
n in
r
wards.
te o
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t.
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Cop py
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rig ht
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Prote AG.
– Remove cover -1- and detach 3-pin connector -arrow- from

flange. ~ 1

– Lift flange slightly and remove seal out of opening in fuel tank.

– Pull fuel gauge sender 2 - G169- upwards a little. Unclip lock‐

ing lugs -arrows- of suction-jet pump.
Installing
• When installing do not bend fuel gauge sender 2 - G169- float
arm.
– Insert fuel gauge sender 2 - G169- into fuel tank.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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rise nte
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nl
pt
du
an
– Push suction-jet pump onto sender inside fuel tank. Suction-
itte
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jet locking lugs -arrows- must engage.
ab
ility
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The remaining installation steps are carried out in the reverse se‐
wit
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quence of removal. The following should be observed:
h re
hole
spec
– Make sure that oil seal is in correct position.
es, in part or in w
t to the co
rrectness of i
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nf
ercia
o
– Tighten locking ring using wrench - T10202- .
rm
m
atio
m
♦ Moisten seal with fuel only when installing flange.

o
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or c
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rig
ht
pyri by
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cted agen
Prote AG.
– Observe installation position of flange -B-. A B

tank -arrow-.
Torque settings

4 Plug-in connectors
⇒ “4.1 Separating plug-in connectors”, page 46
4.1 Separating plug-in connectors

♦ Lever - T10468-
T10468
lkswage es n
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byV ua
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ss
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I VV00-11275 I
du
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ab
Assignment of plug-in connectors:
ility
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Note
spec
es, in part or in w
♦ The plug-in connectors for fuel, vacuum and breather lines are t to the co
colour coded. There is either a coloured dot on the plug-in
connector or the release button is of the respective colour
rrectness of i
⇒ page 46 .
l purpos
♦ Plug-in connectors for fuel lines must engage »audibly« when

joined.
nform
ercia
♦ Ensure plug-in connector is secured properly by pulling it.

m
at
om
io
Colour assignment
n
c
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or
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Plug-in connector Colour code on plug-in connector

at
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Fuel supply black

um
for
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ng
t.
Fuel return line blue
yi Co
Cop py
.
Breather White, beige
t rig
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Vacuum green
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A CAUTION

Version 1 AG. Volkswagen AG d

agen oes
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Plug-in connector by V with release buttons -arrows-oon
ol n t
gu right and
ara
left:
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an
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itte
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ility
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hole
spec
I N20-1 0884 I
es, in part or in w
t to the co
Open
Counterhold at the coupling point for fuel -1- in the engine com‐
rrectness of i
partment.
l purpos
– Insert lever - T10468- between heat shield and stop -arrow- of

fuel line -2- and counterhold.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
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by
cted agen
Prote AG.
Continuation for all connections in the fuel system:

– Push plug-in connector -1- in -direction of arrow A-.
1
– 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 46 .
Plug-in connectors for fuel lines must engage »audibly« when
joined.
• B
– Ensure plug-in connector is secured properly by pulling it.
I N20-1 0883 I
4. Plug-in connectors 47
Version 2
Plug-in connector with pull-release mechanism -arrow-.
Open
– Push plug-in connector -1- in -direction of arrow A-.
– Pull pull-release mechanism -2- in -direction of arrow B-.
– Pull plug-in connector -1- off fuel line -3- in
-direction of arrow B-.
joined.
Version 3 AG. Volkswagen AG d

agen oes
olksw not
Plug-in connector with button ind bfront
yV -arrow- gu
ara
ise nte
r
Open ut
ho eo
ra
s a c
s
– Press release button -arrow- and pull off plug-in connectors.
ce
e
nl
pt
du

an
itte
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erm
ab

ility
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joined.
wit
, is n
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– Ensure plug-in connectors are secure properly by pulling.

hole
spec
I I
es, in part or in w
N20-1 0898
t to the co
Version 4
Plug-in connector with release button -arrows- on right and left:
rrectness of i
Open
l purpos
– Push plug-in connector in -direction of arrow A-.

nform
ercia
– Press release buttons -arrows- and pull off plug-in connector.

m
at
om

ion
c
in t
or

his
ate
joined.
do
priv
cum
or

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

Version 5
Plug-in connector with release buttons -arrows- on right and left:
Open
joined.
Version 6
Plug-in connector with release buttons -arrows- on right and left:
Open
– Push plug-in connector -1- in -direction of arrow- and maintain
pressure.
joined.
Version 7
Plug-in connector -1- with release buttons -2- on right and left:
Open
– Press plug-in connector -1- in -direction of arrow A- and main‐
tain pressure. en AG. V
olkswagen AG
ag does
ol ksw not
– Press release button -2- in -directiony V of arrow B- and pull off gu
db ara
plug-in connector -1-. rise nte
ho eo
ut
Note colour assignment during
ss installation ⇒ page 46 .
a ra
c
ce
e

nl
pt
du
an
joined.
itte
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ab

ility
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CAUTION
h re
hole
spec

es, in part or in w
t to the co

– Check all connected lines for secure fit by pulling.
rrectness of i

l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
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by
cted agen
Prote
49
AG.
4. Plug-in connectors
AG. Volkswagen AG d
agen oes
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5 Fuel filter d by Vol not
gu
ara
rise nte
o
⇒ “5.1 Assembly overview - fuel filter”,
aut page 50
h eo
ra
ss c
⇒ “5.2 Removing and installing fuel filter”, page 52
ce
e
nl
pt
du
an
⇒ “5.3 Fuel hoses in the engine compartment”, page 56
itte
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ab
5.1 Assembly overview - fuel filter
ility
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⇒ “5.1.1 Assembly overview - fuel filter, engine codes CAYC,
h re
hole
CFFA, CFFB, CFGB, CLLA, CFGC”, page 50
spec
es, in part or in w
⇒ “5.1.2 Assembly overview - fuel filter, engine codes CUVC,
t to the co
CUWA”, page 51
5.1.1 Assembly overview - fuel filter, engine codes CAYC, CFFA, CFFB, CFGB,
rrectness of i
CLLA, CFGC
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1 - Supply line
nf
ercia
orm
❑ From fuel tank
m
1 2 3 5
atio
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om
2 - Supply line
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❑ To high-pressure pump
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3 - Return line __..,-.,., I
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❑ From fuel pressure reg‐

t. __..,./
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ulating valve - N 276- . C py
t. rig
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4 - Bolt for upper part of fuel fil‐ cop Vo
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ter cted agen
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❑ Removing upper part of I i
fuel filter ⇒ page 51 i I
❑ 5 Nm i I
i
5 - Filter insert i i
I
6 - Lower part of fuel filter I
i
i i
7 - Fasteners for securing to ) I
body i __..,
__.., i --6
I __..,
❑ 10 Nm il__.., __..,
__..,

Removing upper part of fuel filter

– Unscrew bolts in the sequence shown.
– Collect any escaping fuel.
5.1.2 Assembly overview - fuel filter, engine codes CUVC, CUWA
1 - Fuel filter
⇒ page 53 5 6 7 8 9
❑ Observe notes refer‐ 4~
ence fuel hoses in the
engine compartment
i
I
I
⇒ page 53 . 3 I
agen
I AG. Volkswagen AG d
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2 - Filter element db
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❑ Removing and installingtho r eo
⇒ Maintenance ; Book‐ ss
au ra
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let 821
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un
pt
❑ To do this, remove and
an
d
itte
2
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install the upper part of
rm
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fuel filter
pe
ility
⇒ Item 3 (page 51) .
ot
wit
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3 - Upper part of fuel filter h re

hole
spec
❑ With connections
es, in part or in w
t to the co

⇒ page 54
❑ Observe notes refer‐
rrectness of i

engine compartment
l purpos
⇒ page 56 . 1
nform
ercia
4 - Bolt
❑ Qty. 5
m
a
com
ti
l
o
❑ 5 Nm
n in
4 11
r
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5 - Hose clip
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❑ Release with hose clip
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pliers - V.A.G 1921-

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6 - Fuel supply hose t. C "'- --.._II py
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❑ To high-pressure pump p by
co Vo
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❑ Observe notes refer‐
cted agen
Prote AG. 1 r.12a-1 am2 1
engine compartment ⇒ page 56 .
7 - Fuel return hose
❑ Observe notes reference fuel hoses in the engine compartment ⇒ page 56 .
❑ From engine
8 - Fuel return hose
❑ From high-pressure pump to fuel tank.
5. Fuel filter 51
❑ Separate plug-in connectors ⇒ page 46 .
9 - Fuel supply hose
❑ From fuel tank
❑ Separate plug-in connectors ⇒ page 46 .
10 - Bolt
❑ Qty. 2
❑ 8 Nm
11 - Guide bush
❑ Locks fuel filter in place on pin at engine mounting
5.2 Removing and installing fuel filter

⇒ “5.2.1 Removing and installing fuel filter, engine codes CAYC,
CFFA, CFFB, CFGB, CLLA, CFGC”, page 52
⇒ “5.2.2 Removing and installing fuel filter, engine codes CUVC,
CUWA”, page 53
5.2.1 Removing and installing fuel filter, en‐

gine codes CAYC, CFFA, aCFFB,
gen AG
. VoCFGB,
lkswagen AG
does
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CLLA, CFGC ol not
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ris
Removing ho eo
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pt
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du
Note an
itte
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ab
If the fuel filter only has to be removed to gain space, leave the
ility
ot p
fuel hoses on the fuel filter and high-pressure pump, if possible.

wit
, is n
Place the fuel filter with the hoses connected on the engine to
h re
hole
avoid having to replace them unnecessarily.

spec
es, in part or in w
t to the co
– Open quick-release fasteners -A- and -B- of fuel lines.

rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
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thi
te
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t.
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– Unclip bracket for coolant hose -1-. . Cop py
rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

– Open the clamps and pull off the fuel hoses -2 … 4-, discon‐
nect plug -1- on the fuel temperature sender - G81- .
– Unscrew securing bolts or nut ⇒ Item 7 (page 50) (7).
– Take fuel filter out upwards.
Installing
Install in reverse order. The following should be observed:
♦ Rout fuel hoses free of kinks.
♦ Ensure fuel hoses are seated correctly.
♦ Do not interchange fuel supply and return lines (return line is
blue or with blue markings and supply line is white or with white
markings). AG. Volkswagen n AG do
wage es n
olks
♦ Clip fuel and coolant hoses into retainers again. ot g
yV b ua
ed ran
tho
ris
– Bleed fuel system ⇒ Rep. gr. 23 ; Injection system; Filling/ tee
or
bleeding fuel system . s au ac
s
ce
le
un
pt
an
d
Note
itte
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rm
ab
pe
ility
ot
wit
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joined.
h re
hole
spec
♦ Note colour assignment when installing the plug-in connectors
es, in part or in w
⇒ page 46 .
t to the co
♦ Separate plug-in connectors ⇒ page 46 .
rrectness of i
l purpos
5.2.2 Removing and installing fuel filter, en‐
nform
gine codes CUVC, CUWA
mercia
a
com
tion in
r

te o
thi
s
iva
do
V.A.G 1921
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by
cted agen
Prote AG.
I W00-11169 I
Removing
– Observe notes reference fuel hoses in the engine compart‐
ment ⇒ page 56 .
5. Fuel filter 53
Removing fuel filter to make space:
CAUTION
G. Volkswagen
The fuel system is pressurised. lkswagen A AG do
es n
Vo ot g
Danger of injury through fuel d spray.
by ua
ran
ir se tee
utho
or
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ss
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le
un
pt
an
d

itte
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rm
ab
pe
ility
ot
– Pull off fuel supply line -B-. Separate plug-in connectors
wit
, is n
⇒ page 46 .
h re
hole
spec
– Unclip fuel lines from retainer, and lay them to one side.
es, in part or in w
t to the co
– Loosen bolt -2-, and unscrew it slightly.
– Unscrew bolt -3-.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
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iva
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cum
fo
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ng
t.
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op
– Open retainer -arrow- and unclip fuel lines -1-.
C py
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– Then, lay fuel filter to one side. cop Vo
by lksw
cted agen
Prote AG.
Opening fuel filter:

– Unscrew bolts -arrows- in sequence shown -1- to -5-.
– Remove upper part of fuel filter -1- from fuel filter housing
-2-.
– Lay fuel filter upper part -1- aside with fuel lines still attached.

AG. Volkswagen AG d
agen oes
Renewing fuel filter: olksw not
V gu
d by ara
e
– Remove fuel hoses -5- to -7-. ho ris nte
eo
aut ra
– To do so, release hose clipss using hose clip pliers - V.A.G
s c
1921- .
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nl
pt
du
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itte
– Loosen bolt -2-, and unscrew it slightly.
y li
erm
ab
ility
– Unscrew bolt -3-. ot p
wit
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– Remove fuel filter housing.
h re
hole
spec
es, in part or in w
t to the co
Installing
Install in reverse order. The following should be observed:
rrectness of i
l purpos
Note
nf
♦ Observe notes reference fuel hoses in the engine compart‐
ercia
o
ment
rm
m
atio
⇒ “5.3 Fuel hoses in the engine compartment”, page 56 .
om
n in
c
♦ Secure hose connections with hose clips of the same standard

or
thi
e
as that used during production ⇒ Electronic parts catalogue .

t
sd
iva
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rp
cu
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m
f
en
ng
t.
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– Fit retainer under bolt -2-.
Co
Cop py
t. rig
– Make sure that guide -4- is properly seated on pin.
gh ht
pyri by
Vo
o
by c lksw
– Bleed fuel system ⇒ Rep. gr. 23 ; Injection system; Filling/ cted agen
Prote AG.
Torque settings
♦ ⇒ “5.1.2 Assembly overview - fuel filter, engine codes CUVC,
CUWA”, page 51
5. Fuel filter 55
5.3 Fuel hoses in the engine compartment
Note
♦ The connectors for the fuel hoses on the fuel filter -1- and fuel
temperature sender -2- have been given a 2-ribbed section
-arrow- and bite edge. This reduces the likelihood of fuel sys‐
tem leaks.
♦ When the fuel hoses are removed, the very thin sealing layer
on the inside of the fuel hoses is damaged.
♦ This damage cannot be detected with the naked eye. After
some time, it leads to leaks in the fuel system.
♦ If other components are just removed, check whether it nisAreal‐
wage
G. Volkswagen AG d
oe
ly necessary to disconnect the fuel system from
y V components
olks s no
t gu
with wave section and engagement lip. ised b ara
nte
r
tho eo
♦ Open a different connection in the fuel
sa
u system in the engine ra
c
compartment. s
ce
le
un
pt
an
d
itte
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joined.
erm
ab
ility
ot p
♦ Note colour assignment when installing the plug-in connectors
wit
is n
⇒ page 46 .
h re
ole,
spec
t to the co
♦ Separate plug-in connectors ⇒ page 46 .
CAUTION
rrectne
After removing fuel hoses from connections with a 2 wave pro‐
s
file section and engagement lip, replace these fuel hoses.
s o
cial p
f inform
If a fuel hose cannot be removed from the connections by hand:
mer
atio
om
n
CAUTION
c
i
or
n thi
te
Never insert a screwdriver or similar tool between the hose and

sd
iva
o
r
the connection!
p
cum
r
fo
en
ng
♦ Risk of damage to the connection - component must be re‐

t.
yi Co
op
newed. C py
t. rig
gh ht
pyri by
Vo
co lksw
by
– Turn fuel hose with suitable pliers and pull off hose. cted agen
Prote AG.
If fuel hose still cannot be removed from the connection:

– Cut only into the textile layer of the fuel hose lengthways and
pull hose off.
• Do not cut the inner rubber layer. If the connection is damaged,
the entire component must be renewed.
[I] Note
♦ Before attaching a new fuel hose, remove grease, oil and dirt
thoroughly from the hose connection. Do not use any metal
tools to do this since they could damage the hose connection.
♦ Attach fuel hose to connection without lubricant and then se‐
cure with spring-type clip.

6 Accelerator pedal
⇒ “6.1 Assembly overview - accelerator module”, page 57
⇒ “6.2 Removing and installing accelerator pedal module GX2 ”,
page 57
6.1 Assembly overview - accelerator module

lkswage es n
o ot g
1 - Connector d byV ua
ran
ir se
❑ Black, 6-pin. utho tee
or
a ac
2 - Gas pedal module - GX2- ss
ce
e
nl
pt
du
– Includes:
an
itte
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♦ Acceleration pedal position
erm
ab
sender - G79-
ility
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wit
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♦ Accelerator position sender
h re
2 - G185-
hole
spec
❑ Openings -A- for re‐
es, in part or in w
t to the co
lease tool.
⇒ page 57
rrectness of i
3 - Bolt
l purpos
❑ 10 Nm
4 - Cap
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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cu
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f
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ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
6.2 Removing and installing accelerator

pedal module - GX2-
6. Accelerator pedal 57
♦ Release tool - T10238-

T10238
I VV0 0- 1 011 0 I
Removing
– Remove cover for steering column -arrows-.
– Lever cover cap -3- out with a screwdriver.

1 2
– Unscrew securing bolt -2-.
wage es n
– Unplug connector -1-. yV
olks ot g
ua
b
ed ran
– Push release tool - T10238- to stop into
thor intended holes as
is
) tee o -~~3
shown in illustration. au ra
c
ss
ce
le
un
pt
an
d
4
itte
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erm
ab
{i: .
ility
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wit
is n
h re
/~
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spec
~'\;\
t to the co
~
~(t--
IL~ l
e_i/ s
rrectne
~ II
N2 0-10509
ss o
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– Remove accelerator module.

inform
mer
Installing
atio
om
n
c
i
or
n thi
te
sd
iva
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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.

– Push connector -2- onto accelerator module -5-.

1 2
– Push accelerator module onto retaining pins -5-.
– Insert centring pin -6- into hole in underbody.
– Secure accelerator module with bolt -2-. ) - ~ ~3
– Fit cap -3-.
4
6 ,Vfl~
;f b;-- s
~ ~ I N2 0-1 0509 I
– Reinstall cover for steering column -arrows-.

– If the accelerator pedal module was replaced, adapt module
to engine control unit ⇒ vehicle diagnostic tester “Guided
functions”.
– If the accelerator pedal module was renewed n Aon
G. Vvehicles
olkswagenwith
AG do
an automatic gearbox, the kick-down lkswage must be reprog‐
function es n
Vo ot g
rammed ⇒ Vehicle diagnostic tester
ed
by “Guided functions”. ua
ra
ris nte
Torque settings utho eo
ra
a c
ss
♦ ⇒ “6.1 Assembly overview - accelerator module”, page 57 ce
e
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
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
6. Accelerator pedal 59
7 Fuel pump
⇒ “7.1 Checking fuel system pressurisation pump G6 ”,
page 60
⇒ “7.2 Removing and installing suction-jet pump”, page 91
7.1 Checking fuel system pressurisation

pump - G6-
⇒ “7.1.1 Checking fuel pressure, engine codes CUVC, CUWA”,
page 60
⇒ “7.1.2 Checking fuel delivery rate, engine codes CUVC, CU‐
WA”, page 66
⇒ “7.1.3 Checking delivery pressure and fuel delivery quantity of
fuel system pressurisation pump G6 , engine codes CFFA, CFFB,
CFGB, CLLA, CFGC”, page 73
⇒ “7.1.4 Delivery pressure of fuel pump, engine code CAYC”,
page 80
⇒ “7.1.5 Checking delivery rate of fuel pump , engine code
CAYC”, page 84
⇒ “7.1.6 Checking current consumption of fuel system pressuri‐
sation pump G6 ”, page 87
⇒ “7.1.7 Checking voltage supply of fuel system pressurisation
pump G6 ”, page 89
7.1.1 Checking fuel pressure, engine codes

CUVC, CUWA
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
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wit
is n
h re
I W00-1 087 4 I
ole,
spec
t to the co

VAS 6551 /5 ...,_ -1
rrectne
. . ._ _ _ _ -2
ss o
cial p
-3
in
-••·----
form
mer
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' -4
n
c
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I VV00-11272 I
p
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t.
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Cop py
t. rig
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Vo
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by
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Prote AG.


V.A.G 1921
I W00-11169 I

3409
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
I W00-11118 I
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
CD NOTICE
hole
spec
Bear in mind that the fuel pump can be activated due to opening
es, in part or in w
t to the co
of a door with the battery connected. Fuel can escape if the
system has been opened. rrectness of i
Test conditions:
l purpos
• Connect battery charger, battery voltage at least 12.5 volts ⇒

Electrical system; Rep. gr. 27 ; Battery; Charging battery .
nform
ercia
• Fuses OK: ⇒ Current flow diagrams, Electrical fault finding and

Fitting locations
m
a
com
tion in
• Fuel pump control unit - J538- OK ⇒ Vehicle diagnostic tester.

r
te o
thi
s
iva
• Fuel filter OK.

do
r
rp
cum
fo
• Ensure that vehicle is placed on a level surface.

en
ng
t.
yi Co
op
• Fuel tank at least 1/2 full. C py
ht. rig
rig ht
py by
• All electrical consumers, e.g. lights and rear window heating,
co Vo
by lksw
cted
must be switched off.
agen
Prote AG.
7. Fuel pump 61
[I] Note
♦ The vehicle must be fuelled with the diesel fuel appropriate for
the time of the year. Summer fuel may coagulate (flock) at very
low winter temperatures.
♦ Diesel fuel sold in the summer is guaranteed to be capable of
filtration down to 0°C.
♦ Diesel fuel sold in the summer/winter transition is guaranteed
to be capable of filtration down to -10°C.
G. Volkswagen AG d
♦ Diesel fuel sold in the winter is guaranteed to be capable of lkswagen A oes
filtration down to -20°C. o not
yV gu
edb ara
ris nte
♦ Test sample, if unsure in winter. ut
ho eo
ra
a c
♦ ss
Expose sample to low ambient temperature for approx. 1 hour.
ce
e
nl
pt
du
♦ If the diesel fuel coagulates at temperatures down to -20°C, it
an
itte
y li
is unsuitable for low temperatures. This coagulation can block
erm
ab
the strainer in the fuel delivery unit as well as the fuel filter.
ility
ot p
wit
, is n
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Test sequence
hole
spec
es, in part or in w
t to the co
– Remove engine cover panel ⇒ Rep. gr. 10 ; Engine cover
panel; Removing and installing engine cover panel .
rrectness of i
– Open clamp -arrow-.
l purpos
A CAUTION
nform
ercia

m
at
om
io
n
c
in t
or
his
ate
do
riv

p
cum
or

f
en
ng
t.
yi Co
Cop py
– Pull fuel supply line -1- off high-pressure pump -2-.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Insert connection fitting - VAS 6551/5-1- into fuel supply line

-1- and secure it with a clip.
– Connect hose - VAS 6551/2- between connecting nipple - VAS
6551/5-1- and connection point -A- of pressure tester (diesel)
- VAS 6551- .
– Connect hose - VAS 6551/5-2- between connection -B- of
pressure tester (diesel) - VAS 6551- and high-pressure pump
-2-.
– Secure hose - VAS 6551/5-2- to high-pressure pump -2- with
. Volkswagen AG
a clip. swa
gen AG does
k not
Vol gu
d by ara
CAUTION ris
e nte
utho eo
ra
Risk of fire due to escaping fuel. ss
a c
ce
e
nl
pt
du
an
– Before testing, check all connected lines for secure fit by itte
y li
erm
ab
pulling.
ility
ot p
wit
, is n
h re
hole
spec
– Switch on pressure tester - VAS 6551- by pressing On/Off
es, in part or in w
button.
t to the co
– Ensure that drain tap -C- on pressure tester - VAS 6551- -1-
is closed.
rrectness of i
– Shut-off valves -A- and -B- on pressure tester - VAS 6551-
l purpos
-1- are open.
nf
ercia
o
A- -B
rm
m
– Select guided function 01 Actuating fuel pump .
atio
om
n in
c
– Select function Check fuel pump delivery pressure/de-

or
thi
e
livery rate .
t
sd
iva
-c
o
r
rp
cu
– Follow instructions on vehicle diagnostic tester .
o
m
f
en
ng
I N20-11041 I
t.
yi Co
Cop py
t. rig
Note
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Read off fuel pressure on pressure gauge - VAS 6551- .

• Specification is min. 4.5 bar.
If specification is not obtained
– Check fuel lines in engine compartment for possible restric‐
tions (kinks), blockages and damages.
– Check fuel lines in engine compartment for leaks.
If no fault is detected:
Check fuel pressure ahead of fuel filter as follows:
Checking fuel pressure before fuel filter:
7. Fuel pump 63
A CAUTION
– Connect hose - VAS 6551/2- between fuel supply line from fuel
tank and connection point -B- of pressure tester - VAS 6551- .
– Connect hose - VAS 6551/1- between connection point -A- of
pressure tester (diesel) - VAS 6551- and fuel line -1- leading
to fuel filter.
CAUTION AG. Volkswagen AG d

agen oes
lksw not
Risk of fire due to escaping fuel. byV
o gu
ara
ed
Risk of severe injuries and burns. horis nte
eo
ut ra
– Before testing, check all connected lines
ss a for secure fit by c
pulling.
ce
le
un
pt
an
d
itte
y li
rm
– Place measuring container down outside vehicle and ensure
ab
pe
ility
that its base is secure.
ot
wit
, is n
– Have a second mechanic ensure that end of hose remains
h re
in measuring container during test and measuring container
hole
spec
does not tip over.
es, in part or in w
t to the co
– Switch on pressure tester - VAS 6551- .
rrectness of i
l purpos
is closed.
nform
ercia
-1- are open.

m
– Repeat function Checking fuel pump delivery pressure/

a
com
tio
delivery rate ⇒ page 63 .

n in
r
te o
thi
If specification is now obtained:

s
iva
do
r
rp
cum
Check fuel filter, renew if necessary ⇒ page 52 .

fo
en
ng
t.
yi Co
If specification is not obtained . Cop py
rig
ht ht
rig
Proceed as follows to check fuel pressure at fuel delivery unit: py by
co Vo
by lksw
cted
Checking fuel pressure on fuel delivery unit:
agen
Prote AG.

individual seats .

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

wedge - 3409- .
CD NOTICE
opened.
– Disconnect fuel return line -1- at flange. Separate plug-in con‐

A CAUTION
tion and carefully loosen the connection. G. Volkswagen
A AG do
agen es n
olksw ot g
yV ua
– Connect pressure tester - VAS 6551/1-ised b and fuel supply line ran
leading to fuel filter by means uof
thor
hose - VAS 6551- . tee
or
a ac
– Connect hose - VAS 6551/2- ss between pressure tester - VAS
ce
le
6551- and fuel delivery unit.

un
pt
an
d
itte
y li
erm
ab
ility
ot p
is closed.
wit
is n
– Shut-off valves -A- and -B- on pressure tester - VAS 6551- h re

ole,
-1- are open.

spec
t to the co
– Repeat function Checking fuel pump delivery pressure/ -B

A-
If reading matches specification:
rrectne
– Check fuel lines leading to engine for possible restrictions

s
(kinks), blockages and damages. -c

s o
cial p
f i
– Check fuel lines for leaks.

n
I N20-11041 I
form
mer
If specification is not obtained

atio
om

c
i
or
n thi
te
sd
– Check filter strainer for soiling.

iva
o
pr
cum
r
– Check that all electrical wires are connected correctly.

fo
en
ng
t.
yi Co
– Pull on connectors to check they are firmly seated. Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
7. Fuel pump 65
– Check that all hoses are connected -arrows-.

If no fault is detected:
Note
If the filter strainer is not clogged/soiled, if all lines are connected

and the fuel pressure specification is still not attained, the fuel
delivery unit is defective.
– Renew fuel delivery unit ⇒ page 37 .

I N20-10452 I
7.1.2 Checking fuel delivery rate, engine co‐

des CUVC, CUWA
I W00-1 087 4 I

VAS 6551/5
...... . 1
agen
AG. Volkswagen AG d
oes
-
olksw not
yV gu - - - - - - -2
db ara
rise nte
tho eo
s au r a - - - - -3
- c
s
ce
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un
pt
an
,
.. - - - - · · · -4
d
itte
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rm
ab
pe
ility
ot
I W00-11272 1
wit
, is n
h re
hole
spec

es, in part or in w
t to the co
3409
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
I W00-11118 I
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
66
by c lksw
cted
Rep. gr.20 - Fuel supply system
agen
Prote AG.

V.A.G 1921
♦ Pressure regulating valve - VAS 6551/6-

VAS 6551/6
,,,,
.c::,
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
♦ Vehicle diagnosis
ss and service information system
a ac
ce
e
nl
♦ Measuring container, capacity at least 3 litres

pt
du
an
itte
y li
erm
ab
NOTICE
ility
ot p
wit
, is n
h re

hole
system has been opened.

spec
es, in part or in w
t to the co
Test conditions:
• Connect battery charger, battery voltage at least 12.5 volts ⇒
rrectness of i
Electrical system; Rep. gr. 27 ; Battery; Charging battery .

l purpos
• Fuses OK: ⇒ Current flow diagrams, Electrical fault finding and

Fitting locations.
nform
ercia
• Fuel pump control unit - J538- OK ⇒ Vehicle diagnostic tester.

m
at
• Fuel filter OK.

om
ion
c
in t
r
• Fuel tank at least 1/2 full.

o
his
ate
do
riv

p
cum
for
en
ng
t.
• All electrical consumers, e.g. lights and rear window heating, op
yi Co
C py
t. rig
gh ht
yri by
• Fuel pressure OK ⇒ page 60 . cop Vo
by lksw
cted agen
Prote AG.
7. Fuel pump 67
[I] Note
the time of the year. Summer diesel may coagulate (flock) in
very low winter temperatures.
♦ Diesel fuel sold in the winter is guaranteed to be capable of
filtration down to -20°C.
♦ If the diesel fuel coagulates at temperatures down to -20°C, it
is unsuitable for low temperatures. This coagulation can block
the strainer in the fuel delivery unit as well as the fuel filter.

– Fold front right seat forwards as far as possible. AG. Volkswagen AG d
agen oes
lksw not
– Remove rear bench seat ⇒ General body repairs, by Vinterior;
o gu
ara
Rep. gr. 72 ; Rear seats; Removing and installing
ris bench seat /
ed
nte
o
individual seats . aut
h eo
ra
ss c
ce
A
e
CAUTION
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
– Open clamp -arrow- of fuel supply line -1-.

rrectness of i
– Pull fuel supply line -1- off high-pressure pump -2-.
l purpos
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.

– Fit connection fitting - VAS 6551/5-1- in supply line and secure

it with clamp.
– Connect hose - VAS 6551/2- between connection fitting - VAS
6551/5-1- and connection point -A- of pressure tester (diesel)
- VAS 6551- .
– Connect pressure regulator valve - VAS 6551/6- to connection
-B- of pressure tester - VAS 6551- .
A CAUTION
– Before testing, check all connected lines for secure fit by
pulling.
does not tip over.
– Hold end of hose of pressure regulating valve - VAS 6551/6-

in measuring container.
button.
is closed.
-1- are open.
– Select guided function 01 Actuating fuelswpump
agen .
AG. Volkswagen AG d
oes
lk n o ot g
yV
– Select function Check fuel pump idelivery
ed
b pressure/de- ua
ran
rs tee
livery rate . utho
or
sa ac
– Follow instructions on vehicle sdiagnostic tester .
ce
e
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
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
69
AG.
7. Fuel pump
– Adjust pressure to 4.5 bar with pressure regulating valve - VAS

6551/6- .
– Set pressure regulating valve - VAS 6551/6- to feed pressure
using adjuster wheel -arrow-.
• Specification: 4.5 bar.
– From this point on do not move position of adjuster wheel
-arrow-. VAS 6551/6
– Drain measuring container.

delivery rate .
Note
kswage es n
The fuel system pressurisation pump - G6- is now activated ot g for
ol
byV ua
30 seconds. o
ir se
d ran
tee
th or
au ac
s
– Check quantity delivered in measuring container.
s
ce
le
un
pt
• Specification: fuel delivery rate 1100 cm 3/30 s.
an
d
itte
y li
erm
ab
If the fuel delivery rate is not reached:
ility
ot p
wit
– Check fuel lines in engine compartment for possible restric‐
is n
h re
tions (kinks), blockages and damages.
ole,
spec
– Check fuel lines in engine compartment for leaks. t to the co

If no fault is found:
Check fuel delivery rate before fuel filter as follows:
rrectne
Checking fuel delivery rate ahead of fuel filter:

ss o
cial p
f in

form
mer
A_CAUTION
atio
om
n
c
i
or
n thi

te
sd
va

i
o
pr
cum
r
fo

en
ng
t.
yi Co
op
– Wear protective gloves. C py
t. rig
gh ht
– To release pressure, wrap a clean cloth around the connec‐ yri
p by
o Vo
c by lksw
cted agen
Prote AG.

– Connect hose - VAS 6551/2- to fuel supply line coming from

fuel tank.
– Connect hose - VAS 6551/2- to connection point -A- of pres‐
sure tester (diesel) - VAS 6551- .
A CAUTION
pulling.
does not tip over.

– Switch on pressure tester - VAS 6551- by pressing
agen
G. Volkswagen AG d
On/Off
A
oes
button. yV
olksw not
g b ua
ed ran
oris tee
– Ensure that drain tap -C- on pressure
au
th tester - VAS 6551- -1- or
ac
is closed. ss
ce
e
nl
pt
du
an
itte
-1- are open.
y li
erm
ab
ility
ot p
A- -B
wit
, is n
h re
hole
If the fuel delivery rate is now reached:

spec
es, in part or in w
Check fuel filter, renew if necessary

⇒ “5.2 Removing and installing fuel filter”, page 52 . t to the co -c
If reading again does not match specification: I N20-11041
rrectness of i
Proceed as follows to check fuel delivery rate at fuel delivery unit:

l purpos
Checking fuel delivery rate on fuel delivery unit:

nform
ercia

m
at
individual seats .
om
ion
c
in t
or
his
e
– Unclip cover -1- at retaining tabs -arrows-, using removal

at
do
riv
wedge - 3409- .
p
cum
for
en
ng
t.
CD NOTICE
t. Cop
yi Co
py
rig
gh ht
pyri by
co Vo
by lksw
cted
system has been opened.
agen
Prote AG.
I A20-10835 I
7. Fuel pump 71
– Disconnect fuel return line -1- at flange. Separate plug-in con‐

A CAUTION
ksw
agen
AG. Volkswagen AG d
oes
not
The fuel system is pressurised. by Vol
gu
ara
d
Danger of injury through fuel spray. rise nte
tho eo
u ra
– Wear protective goggles. ss a c
ce
le
un
pt
an
d
itte
y li
tion and carefully loosen the connection. rm
ab
pe
ility
ot
wit
, is n
h re
– Connect hose - VAS 6551/2- to fuel supply line connection on
hole
spec
fuel delivery unit.
es, in part or in w
t to the co
– Connect hose - VAS 6551/2- to connection point -A- of pres‐
sure tester - VAS 6551- .
rrectness of i
l purpos
CAUTION
nform
ercia

m
a
com
tion in
r
te o
thi
pulling.
s
iva
do
r

rp
cum
fo
en
g

n
t.
yi Co
that its base is secure. Cop py
t. rig
gh
ht
pyri by
Vo
o
c by lksw
cted agen
does not tip over. Prote AG.

button.
is closed.
-1- are open.
– Repeat function Checking fuel pump delivery pressure/ -B
A-
If the fuel delivery rate is now reached:
– Check fuel lines for possible restrictions (kinks), blockages
and damages.
– Check fuel lines for leaks. I N20-11041 I
If reading again does not match specification:
– Check filter strainer for soiling.

– Check that all hoses are connected -arrows-.

Only if no fault has yet been detected:
– Renew fuel delivery unit ⇒ page 37 .
I N20-10452 I
7.1.3 Checking delivery pressure and fuel de‐

livery quantity of fuel system pressuri‐
sation pump - G6- , engine codes CFFA,
CFFB, CFGB, CLLA,oCFGC lksw AG. V agen AG
agen does
Voequipment
lksw required not
gu
y
db ara
♦ Pressure gauge -orVAS
ise 6551- nte
eo
th
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
/1
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
I W 00-1 087 4 I
rrectness of i

l purpos
VAS 6551 /5 ...,_ -1

nform
ercia
- -2
m
at
om
io
- - -3
n
c
in t
or
...
his
ate
do
priv
I -4
um
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
I W00-11272 I
p by
co Vo
by lksw
cted agen
Prote AG.
V.A.G 1921
I W00-11169 I
7. Fuel pump 73

♦ Pressure tester (diesel) - VAS 6551-
AS 6551
♦ Vehicle diagnostic tester

♦ Connecting nipple - VAS 6551/5-1-
agen
AG. Volkswagen AG d
o w es n
olks ot g
♦ Hose - VAS 6551/2- d by V ua
ran
e
ris tee
♦ Hose - VAS 6551/1-
ut
ho or
a ac
ss
ce
le
un

pt
an
d
seats .
itte
y li
erm
ab
– Raise cover of fuel delivery unit.

ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
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.

– Check that plug connector -arrow- is fitted securely by pulling

the plug connector without pressing the catch. If connector
was not inserted correctly, repeat function test.
Test specification:
AG. Volkswagen AG d
• Fuses must be OK. agen oes
olksw not
byV gu
ara
d
• Connect battery charger to ensure sufficient voltage
orise supply of nte
min. 12.5 V. aut
h eo
ra
ss c
• Minimum filling level of fuel tank: 15 l.
ce
le
un
pt
an
d
itte
y li
erm
ab
• Ensure that fuel hoses and lines in engine compartment and
ility
ot p
on underbody are not closed through damage (kinks).
wit
is n
h re
ole,
spec
t to the co
Note
rrectne
♦ Note that various fuel filters require the fuel lines be connected
to them in different ways.
ss o
♦ Mark the positions of the fuel hoses on the fuel filter, and note
cial p
f in
them for reinstallation.
form
mer
atio
om
n
c
i
or
n
thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
op
♦ Diesel fuel sold in the summer/winter transition is guaranteed C py
ht. rig
to be capable of filtration down to -10°C. rig ht
py by
co Vo
by lksw
♦ Diesel fuel sold in the winter is guaranteed to be capable of Prote
cted AG.
agen
♦ Test a sample, if unsure in winter. Expose sample to low am‐
bient temperature for approx. 1 hour. If the fuel flocculates at
temperatures of up to-20°C, diesel fuel is not suitable. Diesel
fuel is not suitable for use at low temperatures. This coagula‐
tion can block the strainer in the fuel delivery unit as well as
the fuel filter.
CAUTION
Test sequence for high-pressure pump

7. Fuel pump 75
– Open clamp and pull fuel supply line -arrow- off the high-pres‐
sure pump.
– Place connecting nipple - VAS 6551/5-1- in supply line and
secure with clamp.
– Connect hose - VAS 6551/2- between connecting nipple - VAS
6551/5-1- and connection point »A« of pressure tester (diesel)
- VAS 6551- .
– Connect hose - VAS 6551/1- to connection point »B« of pres‐
,A CAUTION
pulling.
– Take any fuel-soaked cloths away wagefrom area of vehicle.
es n
olks ot g
– Place measuring container d by Vdown outside vehicle and ensure ua
ran
that its base is secure. o
ir se tee
th or
– Have a second mechanicau ensure that end of hose remains ac
ss
ce
e
nl
does not tip over.
pt
du
an
itte
y li
erm
ab
– Guide open end of hose - VAS 6551/1- into a suitable meas‐
ility
ot p
urement container.
wit
, is n
– Switch on pressure tester - VAS 6551- . h re

hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Open shut-off taps “A” and “B” of pressure tester - VAS 6551- .
Close shut-off tap “C”.
VAS 6551
– Connect vehicle diagnostic tester and then carry out “Guided
Fault Finding, Checking electrical fuel pump(s)”.
[I] Note
The fuel pump will be activated for 30 seconds.
– Carefully close shut-off tap “B” and set pressure of 4.5 ± 0.1
bar. I N20-1 07 10 I
[I] Note
If the specified pressure is not reached, carry out “test sequence

for fuel filter” ⇒ page 77 . Reason may be a blocked fuel filter.
– Once pressure has been set, empty measuring beaker. Carry

out Guided Function “Check electric fuel pump(s)” again.
– Observe pressure on pressure tester - VAS 6551- .
– After controlling pump (30 seconds), read supplied fuel quan‐
tity in measurement container. Specification: min. 1100 ml.
If the specifications are attained: fuel system pressurisation pump
- G6- OK.
If the specified value is not attained, carry out test sequence for
fuel filter ⇒ page 77 .
Test sequence for fuel filter
– Reconnect fuel supply line to high-pressureenpump.
AG. Volkswagen AG
wag does
olks not
yV gu
– Pull off fuel supply line -B-. To isdo
ed this, press quick-release
b ara
nte
couplings onto connections,uthpress in locking elements (keep
or eo
ra
pressed) and pull off quick-release
ss a couplings. Separate plug- c
in connectors
ce
e
nl
pt
⇒ “4.1 Separating plug-in connectors”, page 46 .

du
an
itte
y li
– Connect hose - VAS 6551/2- between fuel line from fuel tank
erm
ab
ility
and connection point “A” of pressure tester - VAS 6551- .

ot p
wit
, is n
– Connect hose - VAS 6551/1- to connection point “B” of pres‐

h re
hole

spec
es, in part or in w
'A
t to the co
CAUTION
rrectness of i

l purpos
pulling.
nf
ercia
or

m
m
atio

om
n in
c

or
thi
e

t
sd
iva
does not tip over.

o
r
rp
cu
o
m
f
en
ng
t.
yi
Co
Cop py
urement container. ht. rig
rig ht
py by
o Vo
– Switch on pressure tester - VAS 6551- . by c lksw
cted agen
Prote AG.
7. Fuel pump 77
VAS 6551
[I] Note
bar. I N20-1 07 10 I
[I] Note
If the specified pressure is not reached, carry out

gen AG. V“test sequence
olkswagen AG
does
swa
at flange of fuel delivery unit” ⇒ page y V 78 . Reason: fuel line may
olk not
gu
be pinched or kinked. ised b ara
nt
r ee
ho
aut or
ac
– Once pressure has empty measuring beaker. Carry been
ss set,
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
If the specifications are attained: Fuel system pressurisation
spec
pump - G6- OK, renew fuel filter element ⇒ Maintenance ; Book‐
es, in part or in w
t to the co
let .
If the specified value is not achieved, carry out test sequence on
the flange of the fuel delivery unit ⇒ page 78 . rrectness of i
Test sequence on the flange of the fuel delivery unit
l purpos
nform
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.

AG. Volkswagen AG d
agen oes
o lksw not
– Pull fuel supplyd by Vline (black or black marking) -3- goff
ua fuel delivery
ran
unit. Separate
orise plug-in connectors ⇒ page 46 . tee
h
aut or
ac
ss
ce
le
Note
un
pt
an
d
itte
y li
erm
Press in securing ring to release the fuel lines.
ab
ility
ot p
wit
is n
– Collect escaping fuel with a cleaning cloth.
h re
ole,
spec
– Connect hose - VAS 6551/2- between fuel line on the flange
and connection point “A” of pressure tester - VAS 6551- .
t to the co
– Connect hose - VAS 6551/1- to connection point “B” of pres‐
rrectne
A CAUTION
ss
o
cial p
f in
form
mer
atio
m
pulling.
o
n
c
i
or
n
thi
te
sd
a

iv
o
pr
that its base is secure. cum

r
fo
en
ng
t.
yi Co
op
C py
t. rig
gh
does not tip over.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
urement container.
7. Fuel pump 79
VAS 6551
[I] Note
bar. I N20-1 07 10 I
[I] Note
If the specified pressure is not reached, check the current olks
draw
wage es n
ot g
of the fuel pump by V ua
ed ran
⇒ “7.1.6 Checking current consumption of fuel system
oris pressuri‐ tee
sation pump G6 ”, page 87 . au
th or
ac
ss
ce
e
nl
– Once pressure has been set, empty measuring beaker. Carry
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
If the specifications are attained: fuel system pressurisation pump
t to the co
- G6- OK., check that fuel line to engine is not kinked or crushed
and renew as necessary.
rrectness of i
If the specified value is not achieved, check the voltage supply for
the fuel pump
l purpos

pump G6 ”, page 89 .
nform
ercia
7.1.4 Delivery pressure of fuel pump, engine

m
at
om
code CAYC ion

c
in t
or
his
te

a
do
priv
cum
or
♦ Vehicle diagnostic tester VAS 6551/5

f
en
ng
t.
yi Co
♦ Hose adapter - VAS 6551/5-2- t. Cop py
rig
gh ht
yri
♦ Hose adapter - VAS 6551/5-3- p by
o Vo
by c lksw
cted agen
♦ Adapter - VAS 6551/5-1- Prote AG.
Hose adapter set - VAS 6551/5-
I W00-1 09 44 I

Pressure tester - VAS 6551-

Test specification: VAS 6551
• Fuses must be OK.
• Battery voltage at least 12 V
• The fuel level is not important for this measurement. However,
the fuel tank should have at least 5 litres of fuel.
• Ensure that fuel hoses and lines in engine compartment and
on underbody are not closed through damage (kinks).
CAUTION
Test sequence swage

es n
olk ot g
yV
– Remove engine cover panel ⇒ Rep. gr. d 10 ; Engine cover
b ua
ran
ir se
panel; Removing and installing enginetho cover panel . tee
or
au ac
– Join hose adapter - VAS 6551/5-2- and adapter - VAS ss
ce
le
6551/5-4- .
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
– Pull fuel supply line -arrow- off the high-pressure pump.
wit
, is n
h re
– Integrate the pressure tester - VAS 6551- together with the
hole
following adapters: spec

es, in part or in w
t to the co
♦ Hose adapter - VAS 6551/2-
♦ Adapter - VAS 6551/5-1-
rrectness of i
♦ Hose adapter - VAS 6551/5-2-

l purpos
nform
mercia
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.
7. Fuel pump 81
– Connect pressure tester - VAS 6551- to fuel circuit as shown.
CAUTION
pulling.
– Open shut-off valves “A” and “B” of pressure tester - VAS

6551- . Close shut-off tap “C”.
VAS6551
– Connect vehicle diagnostic tester and carry out guided func‐
tion “Checking electronic fuel pump(s)”. G. Volkswage nA n AG d
wage oes
Volks not
gu
by
[I) Note
thoris
ed
ara
nte
eo
s au ra
c
s
ce
le
un
pt
an
d
itte
– Take pressure reading on pressure tester - VAS 6551- . Spec‐
y li
rm
ab
ification: Min. 4.5 bar. I N20-1 07 10 I
pe
ility
ot
wit
– Start engine and allow it to run at idling speed.
, is n
h re
hole
– Take pressure reading on pressure tester - VAS 6551- . Spec‐ spec

ification: Min. 4.5 bar.
es, in part or in w
t to the co
– Place pressure tester - VAS 6551- onto windscreen so that it

can be read from inside of vehicle.
rrectness of i
– Increase idling speed to 2500 rpm.

l purpos
– Read pressure on pressure tester - VAS 6551- . Specification:

min. 4.5 bar
nform
ercia
If specification is not reached, check must be repeated in front of

fuel filter. This checks whether the fuel filter is clogged.
m
a
com
tio
If no pressure builds up, first check voltage supply

n in
r
te o

thi
s
iva
pump G6 ”, page 89 and current draw

do
r
rp
⇒ “7.1.6 Checking current consumption of fuel system pressuri‐

um
fo
sation pump G6 ”, page 87 of fuel delivery unit.

en
ng
t.
yi Co
op
– Reconnect fuel supply line to high pressure pump.
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Pull off fuel supply line -B-. To do this, press quick-release

couplings onto connections. Separate plug-in connectors
⇒ “4.1 Separating plug-in connectors”, page 46 .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
– Connect pressure tester - VAS 6551- to
s lines -VAS 6551/1-
s c
and -VAS 6551/2- in fuel circuit.
ce
e
nl
pt
du
an
itte
y li
A CAUTION
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
pulling.
t to the co
rrectness of i
Make sure that couplings engage correctly.
l purpos

– Perform pressure measurement as in previous check.
nform
ercia
Pressure reading should be at least 4.6 bar.

m
at
om
io
♦ If specified pressure values are obtained
n
c
in t
or
his
e
♦ If difference in measured pressure value (before filter and after

at
do
riv
filter) ≥0.4 bar

p
cum
for
en
g
– Renew filter ⇒ Maintenance ; Booklet .

n
t.
yi Co
Cop py
♦ If specified pressure values are not obtained
t. rig
gh ht
pyri by
Vo
o
♦ Perform measurement directly on fuel delivery unit.
by c lksw
cted agen
Prote AG.
– Reconnect push-fit connector to fuel filter.
Ensure for secure engagement of coupling.

7. Fuel pump 83
– Pull fuel supply line (black or black marking) -3- off fuel delivery
unit. Separate plug-in connectors ⇒ page 46 .
AG. Volkswagen AG d
agen oes
olksw not
Note d by
V gu
ara
ise nte
or eo
h
Press in securing ring to release the fuel lines. aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Connect connection -A- of pressure tester - VAS 6551- with
es, in part or in w
line -VAS 6551/1- to open end of fuel delivery unit.
t to the co
VAS 6551
– Open shut-off taps “B” + “C” of pressure tester - VAS 6551- .
rrectness of i
l purpos

tion “Checking electronic fuel pump(s)”.
nf
ercia
orm
[I]
m
Note
atio
om
n in
or c
The fuel pump will be activated for 30 seconds. I N20-1 07 10 I
thi
te
sd
iva
o
r
rp
cu
– Take pressure reading on pressure tester - VAS 6551- . Spec‐
o
m
f
en
ng
ification: 7.2 ± 0.5 bar.

t.
yi Co
Cop py
If specified pressure is not reached, or if specified pressure drops
t. rig
gh ht
yri
completely or temporarily, following faults may be present: p by
o Vo
by c lksw
cted agen
♦ Battery voltage below 12.5 V (connect charger) Prote AG.
♦ Delivery rate of fuel pump too slow. Check ⇒ page 84 .

♦ Voltage supply of fuel pump faulty. Check ⇒ page 89 .
♦ Current consumption of fuel pump too low. Check
⇒ page 87 .
♦ Fuel delivery unit filter strainer soiled. In order to check it, re‐
move fuel delivery unit ⇒ page 37 .
♦ Quick-release coupling in the fuel delivery unit defective. In
order to check it, remove the fuel delivery unit ⇒ page 37 .
7.1.5 Checking delivery rate of fuel pump , en‐

gine code CAYC
♦ Vehicle diagnostic tester VAS 6551/5

♦ Adapter - VAS 6551/5-1-
Hose adapter set - VAS 6551/5-
I W00-1 09 44 I

Pressure tester - VAS 6551-
VAS 6551
I N20-1 07 10 I
Test instrument adapter/DSO (5-pin) - VAS 5565-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
I 'N0 0- 1 05 9 9 I
nl
pt
du
an
itte
y li
erm
ab
Hand multimeter - V.A.G 1526D-
ility
ot p
Test sequence
wit
, is n
h re
hole
• Delivery pressure of fuel pump previously checked
spec
⇒ page 60 .
es, in part or in w
t to the co
• Fuel tank at least 3/4 full.
• Connect charger or battery voltage above 12.5 volts.
rrectness of i
l purpos
nform
mercia
at
– Pull fuel supply line (black or black marking) -3- off fuel delivery
om
io
unit. Separate plug-in connectors ⇒ page 46 .
n
c
in t
or
his
e

at
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.
7. Fuel pump 85
– Connect connection -A- of pressure tester - VAS 6551- with

line -VAS 6551/1- to open end of fuel delivery unit.
VAS 6551
A CAUTION
olkswagen AG
Risk of fire due to escaping fuel. wage
n AG. V does
olks not
Risk of severe injuries and burns. by
V gu
ara
ed nte
ris
– Before testing, check all connected linesth for secure fit by
o eo
pulling. au ra
c
ss
ce
le
un
pt
an
– Place measuring container down outside vehicle and ensure d
itte
y li
erm
I N20-1 07 10 I
ab
ility
ot p
wit
is n
h re
ole,
does not tip over.
spec
t to the co
– From connection -B-, route hose adapter - VAS 6551/2- into a
≤ 3-litre measuring container -3- and hold there.
rrectne
VAS6551
– Open shut-off taps “B” + “C” of pressure tester - VAS 6551- .
ss o
cial p
f
– Switch on ignition.
inform
mer
atio
m
tion “Checking electronic fuel pump(s)”.

o
n
c
i
or
n thi
te
sd
va
Note
i
o
pr
c
I N20-1 07 10 I
um
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
– Carefully open shut-off tap -B- completely. cop Vo
by lksw
cted agen
Prote
– Slowly close shut-off valve -B- while taking pressure reading
AG.
shown on pressure tester - VAS 6551- . Close carefully to set

specification to 5 ± 0.2 bar.
– Drain measuring container.
Repeat function “Checking electronic fuel pump(s)”
The amount of fuel delivered by the fuel pump depends on the
voltage at the fuel delivery unit.
– Therefore, also connect multimeter - V.A.G 1526- to outputs

-1 and 5- of test instrument/DSO adapter 5-pin - VAS 5565- .
Test conditions
• Ambient temperature or fuel temperature: 20°C ± 5°C.
• At a pressure of 5 ± 0.2 bar at flange output
• During the checking process, voltages ranging from 11 to 15
volts must be evident at the fuel pump. Measured at the flange
connector of the delivery unit.
– Carry out in the guided function “Checking electronic fuel
pump(s)”

– Compare the amount of fuel delivered with the read value from mV30S'
the table. 1800
* Delivered amount of fuel in ml/30 s 1600

-
- -
1400
** Voltage at fuel delivery unit (V) with engine stationary and pump 1200
-
running.
~
1000
Reading example:
800
600
During the test, a voltage of 12.0 volts, for example, is measuredAG. Volkswagen400
AG do
agen
at the fuel delivery unit. V olksw 200
es n
ot g
y ua
db 0 r
The delivered amount of fuel is therefore 1100
or ml/30 s.
ise 11V 12Van
tee 13V 14V 15V " )
th o
(V) I N20-1 067 4
au ra I
If the required amount of delivered fuel isssachieved, or if more is c
measured: Fuel pump OK.
ce
e
nl
pt
du
an
If the amount of fuel to be delivered by the fuel pump is not ach‐
itte
y li
erm
ieved, the following faults might have occurred:
ab
ility
ot p
♦ Battery voltage below 12.5 V (connect charger)
wit
, is n
h re
♦ Fuel delivery unit filter strainer soiled. Check filter strainer for
hole
spec
soiling.
es, in part or in w
t to the co
♦ Voltages in the range from 11 to 15 volts were not reached
during the testing process.
rrectness of i
♦ Checking voltage supply of fuel pump
l purpos
pump G6 ”, page 89 .
♦ Check current consumption of fuel pump
nf
ercia
⇒ “7.1.6 Checking current consumption of fuel system pres‐
orm
surisation pump G6 ”, page 87 .
m
atio
om
n in
or c
7.1.6 Checking current consumption of fuel
thi
te
sd
iva
system pressurisation pump - G6-
o
r
rp
cu
o
m
f
en
ng

t.
yi Co
Cop py
t.
rig
gh ht
pyri by
Vo
o
by c
♦ Hand-held multimeter - V.A.G 1526D- or pickup clamp - V.A.G
lksw
cted agen
Prote
1526B/2-
AG.
♦ Test instrument adapter/DSO (5-pin) - VAS 5565-

7. Fuel pump 87
[I] Note
♦ Note that various fuel filters require the fuel lines be connected
to them in different ways.
♦ Mark the positions of the fuel hoses on the fuel filter, and note
them for reinstallation.
♦ Diesel fuel sold in the winter is guaranteed to be capable of
G. Volkswagen AG d
♦ Test a sample, if unsure in winter. Expose sample
lksw
ageto
n Alow am‐ oes
bient temperature for approx. 1 hour. If the by fuel flocculates at
o not
V gu
ara
temperatures of up to-20°C, diesel fuel risis not suitable. Diesel
ed
nte
fuel is not suitable for use at low temperatures.
ut
ho
This coagula‐ eo
ra
tion can block the strainer in the fuel delivery unit as well as
s a c
s
the fuel filter.
ce
le
un
pt
an
d
itte
y li
Test conditions:
erm
ab
ility
ot p
• Connect battery charger to ensure sufficient voltage supply of
wit
is n
min. 12.5 V.
h re
ole,
spec
• Fuel temperature over 10°C
t to the co
Test sequence
– Fold rear seat bench up ⇒ General body repairs, interior; Rep.
gr. 72 ; Rear seat; Removing and installing bench seat / indi‐
rrectne
vidual seats .
s
s o
cial p
f i

nform

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.

– Pull off connector -4-.
– Connect test instrument adapter/DSO (5-pin) - VAS 5565- to

connector and fuel delivery unit.
G. Volkswagen AG d
– Connect pick-up clamp - V.A.G 1526B/2- -A- to red terminal lkswagen A A oes
not
with lettering “pick-up clamp” for test instrument adapter/DSO yV
o gu
db ara
(5-pin) - VAS 5565- . or
ise VAS
nte 5565
th eo
s au ra
c
s
[I]
ce
e
Note
nl
pt
du
an
itte
y li
Pickup clamp of hand-held multimeter - V.A.G 1715- can also be
erm
ab
ility
connected to red terminal with lettering “pickup clamp” of test in‐
ot p
strument adapter/DSO (5-pin) - VAS 5565- .
wit
, is n
h re
hole
spec
– Switch on ignition.
es, in part or in w
t to the co
– Connect vehicle diagnostics tester and then carry out Guided
Fault Finding “Checking electrical fuel pump(s)”.
rrectness of i
[I] Note
l purpos
nf
ercia
orm
m
– Read current consumption on hand-held multimeter - V.A.G
atio
m
1526D- : specification: max. 14.0 amperes.

o
n in
or c
thi
e
If the measured value is not within specifications:

t
sd
iva
o
r
rp
cu
– Remove fuel delivery unit
o
m
f
⇒ “3.2 Removing and installing fuel delivery unit, fuel gauge

en
ng
t.
yi Co
sender”, page 37 . t. Cop py
rig
gh ht
– Check electrical wiring between flange and fuel pump for con‐ yri
p by
o Vo
tinuity.
c by lksw
cted agen
Prote AG.
– Check filter in floor of fuel delivery unit for dirt or clogging.
If no cable break or soiling can be found:
– Renew fuel delivery unit
⇒ “3.2 Removing and installing fuel delivery unit, fuel gauge
sender”, page 37 .
7.1.7 Checking voltage supply of fuel system

pressurisation pump - G6-
♦ Pick-up clamp - V.A.G 1526B/2-
7. Fuel pump 89
♦ Hand multimeter - V.A.G 1526D-

V.A.G 1526 D
AG. Volkswagen AG d
agen oes
olksw not
V gu
by ara
0.
ed
ris nte
♦ Test instrument adapter/DSO (5-pin) - VAS 5565- ut
ho eo
ra
s a c
s
ce
le
VAS55G5
un
pt
an
d
itte
y li
rm
ab
l ~I)
pe
ility
ot
wit
, is n
h re
\; n
hole
spec
es, in part or in w
.--::l
t to the co
rrectness of i
l purpos
Test conditions
• Fuses must be OK.
nform
ercia
• The battery voltage must be at least 12 V; if necessary connect

m
a
a battery charger.
com
tion in
r

te o
thi
s
iva
do
r
rp
cum
• Visual check of cables OK.
fo
en
ng
t.
yi Co
Test sequence Cop py
t. rig
gh ht
yri
– Remove rear bench seat ⇒ General body repairs, interior; p by
o Vo
by c
lksw
cted agen
Prote
individual seats .
AG.

– Pull connector off fuel delivery unit flange.
– Connect test instrument/DSO adapter (5-pin) - VAS 5565- be‐
tween connector and flange.

– Connect hand-held multimeter - V.A.G 1526D- to contacts

-1- and -5- of adapter.
[I] Note
– Read voltage value on hand-held multimeter - V.A.G 1526D- :

specification = approx. battery voltage.
If no voltage is present:
– Check activation of fuel pump relay and wiring for an open or
short circuit ⇒ Vehicle diagnostic tester.
Voltage supply OK.
– Check current consumption of fuel pump ⇒ page 87 .
7.2 Removing and installing suction-jet

pump
T10202
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
I W00-11313 I
hole
spec
es, in part or in w

t to the co
V.A.G 1332
rrectness of i
l purpos
•
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
I W00-11165 1
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.
7. Fuel pump 91
Function of suction-jet pump

The suction-jet pump operates according to the principle of fluid
entrainment: the stream of fuel from the electrical fuel pump is
passed through a nozzle in the suction-jet pump, and is thus ac‐
celerated. The accelerated stream of fuel draws off the surround‐
ing fuel and delivers it to the baffle housing of the fuel delivery
unit.
Faults caused by defective suction-jet pump agen
AG. Volkswagen AG d
oes
olksw not
byV gu
ara
ed
[I] Note
ss aut
horis nte
eo
ra
c
♦ Risk of breakdown due to defective suction-jet pump.
ce
e
nl
pt
du
an
itte
♦ If the suction-jet pump is defective, the engine can stop due to
y li
erm
ab
fuel starvation when the tank is still 1/4 full.
ility
ot p
wit
, is n
h re
If suction-jet pump does not work, approx. 15 litres of fuel remain
hole
in left chamber of fuel tank and cannot be extracted by fuel de‐
spec
es, in part or in w
livery unit.
t to the co
If the engine stops due to fuel starvation with the tank filled up to
about 1/4, proceed as follows:
rrectness of i
– Use ⇒ Vehicle diagnostic tester to check fuel pump.
l purpos
If fuel pump is OK, but no fuel is delivered:

nf
ercia
– Refill fuel tank with approx. 5 litres of fuel. orm

m
– Start engine.
atio
om
n in
c
If engine starts OK now:

or
thi
te
sd
a
– Renew suction-jet pump as described below.

iv
o
r
rp
cu
o
Removing
f
en
ng
t.
yi Co
op
– Pull out fuel delivery unit through opening in fuel tank C py
ht. rig
⇒ “3.2 Removing and installing fuel delivery unit, fuel gauge rig ht
py by
sender”, page 37 .
co Vo
by lksw
cted agen
Prote AG.
– Press securing ring and pull fuel line -A- for suction-jet pump
off.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
autho
CC 2012 ➤ , Passat 2011 ➤ , Passate o Variant
ra 2011 ➤
ss Fuel supply system - diesel engines - Edition 05.2019
c
ce
e
nl
pt
du
an
– Press tab -B- of suction-jet pump in -direction of arrow- and
itte
y li
unclip from fuel delivery unit.
erm
ab
ility
ot p
– Remove fuel gauge sender 2 - G169- ⇒ page 43 .
wit
, is n
h re
– Pull suction-jet pump out from left side of vehicle.
hole
spec
es, in part or in w
– Check that the fuel lines on suction-jet pump are fitted securely
t to the co
and are not damaged.
– Also check suction-jet pump for any dirt.
rrectness of i
Installing suction-jet pump
l purpos
Install in reverse order of removal. The following should be ob‐ I N20~1 0859 I
served:
nf
ercia
o
♦ Fuel lines are to be installed free of kinks.
rm
m
atio
m
♦ Ensure that line connections are tight.

o
n in
or c
Torque settings
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.
7. Fuel pump 93

Fuel Supply System

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Fuel Supply System

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Service

Service Department. Technical Information

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Copyright © 2019 Volkswagen AG, Wolfsburg D3E803ECA74

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.5 Step 5, there are metal particles in high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.6 Step 6, there are no metal particles in high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . 13

2.1 Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.2 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.3 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3 Fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3.3 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

3.4 Removing and installing fuel gauge sender 2 G169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4.1 Separating plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

5.1 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

5.2 Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

5.3 Fuel hoses in the engine compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

1.1 Safety regulations for working on fuel supply

Danger of fire caused by escaping fuel

and cause a fire.

– Disconnect voltage supply to fuel pump before opening the

Observe the fill level of the fuel tank:

may remain in the fuel tank, refer to the corresponding work

♦ If necessary, drain fuel tank

⇒ “2.2 Emptying fuel tank”, page 17 .

♦ If no exhaust gas extraction system is available, a radial fan

To prevent injuries to persons and destruction of the injection and

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

Risk of injury due to unexpected motor start

Risk of injury caused by unsecured testing and measuring instru‐

1.4 Safety precautions when working on the

2 Rep. gr.00 - Technical data

nutes after the ignition is switched off ⇒ Electrical system;

2.1 Engine number/engine data

1) only for India, South America and Russia

Power kW 110 135

4 Rep. gr.00 - Technical data

attention to the following “rules”:

have been kept unpackaged (for example in toolboxes).

♦ Do not move the vehicle.

example from engine bung set - VAS 6122- .

4.1 Pipe/wire routing and attachment

♦ Mark components prior to removal to prevent them from being

installation positions. Where necessary, make sketches or

4.2 General repair instructions

♦ It is used to extract fuel fumes.

♦ If no exhaust gas extraction system is available, a radial fan

with a displacement greater than 15 m3/h can be used provid‐

ing that motor is not in air flow.

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

♦ Interrupt power supply to fuel system pressurisation pump -

G6- ⇒ Current flow diagrams, Electrical fault finding and Fitting

6 Rep. gr.00 - Technical data

20 – Fuel supply system

work steps by means of a flowchart, with various factors being

taken into account.

1.1 Step 1, engine was started with incorrect

1. Procedure should vehicle be misfueled 7

♦ Pressure gauge - VAS 6551-

♦ Adapter set - VAS 6551/5-

♦ Removal wedge - 3409-

♦ Vehicle diagnosis and service information system

extractor - VAS 5190- ⇒ page 17 .

– Remove rear bench seat ⇒ General body repairs, interior;