VW Passat b6 Fuel System Diesel Engines Eng

Service
Workshop Manual
Passat 2006 ➤
Passat Variant 2006 ➤
Fuel supply system - Diesel engines
Engine ID
CAY CBA CBA CBB CBA CBD
C A B B C C
Edition 11.2013
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
20 - Fuel supply system
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2015 Volkswagen AG, Wolfsburg D3E803DE33E

Passat 2006 ➤ , Passat Variant 2006 ➤
Fuel supply system - Diesel engines - Edition 11.2013
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number, engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Safety precautions during road tests in which test and measuring equipment is used . . . . 2
2.2 Safety precautions when working on vehicles with a start/Stop system . . . . . . . . . . . . . . 2
2.3 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Cleanliness specifications for working on the auxiliary/supplementary heater and fuel
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1 Procedure when filling with incorrect fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1 Step 1 (Engine was started with incorrect fuel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Step 2 (Engine was not started with incorrect fuel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3 Step 3 (There are filings in fuel delivery unit and fuel tank) . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4 Step 4 (There are no filings in fuel delivery unit and fuel tank) . . . . . . . . . . . . . . . . . . . . . . 9
1.5 Step 5 (There are filings in high-pressure pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.6 Step 6 (There are no filings in high-pressure pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.1 Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.3 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3 Fuel delivery unit and fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.1 Removing and installing fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . 36
3.2 Removing and installing fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4 Separating plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.1 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.2 Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6 Accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.1 Assembly overview - accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.2 Removing and installing accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7 Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7.1 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7.2 Removing and installing fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
7.3 Removing and installing suction-jet pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Contents i
ii Contents
00 – Technical data
1 Identification
(VRL006302; Edition 11.2013)
⇒ “1.1 Engine number, engine data”, page 1
1.1 Engine number, engine data

Engine code CAYC CBAA CBAB CBBB CBAC CBDC
Emission standards EU 5 EU 5 EU 5 EU 5 EU 5 EU 5
Capacity l 1.6 2.0 2.0 2.0 2.0 2.0
Output kW 77 100 103 125 105 81
Fuel according to DIN EN 590 DIN EN 590 DIN EN 590 DIN EN 590 DIN EN 590 DIN EN 590
1. Identification 1
2 Safety instructions
⇒ “2.3 Safety precautions when working on fuel supply system”,
page 3
⇒ “2.1 Safety precautions during road tests in which test and
measuring equipment is used”, page 2
⇒ “2.2 Safety precautions when working on vehicles with a start/
Stop system”, page 2
2.1 Safety precautions during road tests in

which test and measuring equipment is
used
Note the following if test and measuring equipment has to be used
during a road test:
♦ Always secure test and measuring equipment on rear seat.
♦ Have a second person operate the test and measuring equip‐
ment.
♦ Operate test and measuring equipment from the rear seat.
♦ Do not operate test and measuring equipment from the front
passenger seat.
♦ In the event of an accident, the person may receive serious
injuries when the front passenger airbag is triggered.
2.2 Safety precautions when working on ve‐

hicles with a start/Stop system
WARNING
♦ The engine of a vehicle with an activated start/stop system

can start automatically when the start conditions are met.
♦ This is indicated by a message in the dash panel insert.
♦ Therefore, ensure that the start/stop system is deactivated
when working on vehicle (switch ignition off, switch ignition
on again as required).
2 Rep. gr.00 - Technical data

2.3 Safety precautions when working on

fuel supply system
WARNING
When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route all the various lines and electrical wiring so that they
are in their original positions.
♦ This applies e.g. for fuel, hydraulics, activated charcoal
filter system, coolant and refrigerant, brake fluid, vacuum.
♦ Ensure that there is sufficient clearance to all moving or
hot components.
♦ The fuel and the fuel lines in the fuel system can become
very hot (danger of scalding)!
♦ The fuel system is also under pressure!
♦ Before opening the system place a cloth around the con‐
nection.
♦ Release pressure by carefully loosening the connection.
♦ Wear eye and hand protection when performing any type
of repair work on the fuel system!
WARNING
Bear in mind that the fuel pump can be activated due to open‐
ing of a door with the battery connected. Fuel can escape if the
system has been opened.
When removing and installing fuel gauge sender or fuel pump

(fuel delivery unit) from a full or partly full fuel tank, observe the
following:
♦ 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. This draws away the fuel fumes that
escape. If no exhaust gas extraction system is available, a ra‐
dial fan with a displacement greater than 15 m3/h can be used
providing that motor is not in air flow.
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
WARNING
Danger of burning from very hot fuel is possible.

♦ In extreme cases, the fuel lines and the fuel can reach a
temperature of 100°C. Allow the fuel to cool down before
disconnecting the lines - danger of scalding.
♦ Wear protective gloves.
♦ Wear eye protection.
Risk of injury due to highly-pressurised fuel.
♦ To release pressure in fuel system, place clean cloth
around connection and carefully undo connection.
2. Safety instructions 3
WARNING
The fuel system is pressurised! Wear eye protection and pro‐

tective clothing to avoid eye injuries and skin contact. Before
loosening hose connections, wrap a cloth around the connec‐
tion. Then release pressure by carefully pulling hose off con‐
nection.
WARNING
Do not damage fuel hoses in engine compartment.
Note
♦ Plug-in connectors for fuel lines must engage »audibly« when

joined.
♦ Take note of colour assignment when installing the plug-in
connectors ⇒ page 43
♦ Ensure plug-in connector is secured properly by pulling it.
♦ Separate plug-in connectors ⇒ page 43 .
4 Rep. gr.00 - Technical data

3 General notes
⇒ “3.1 Cleanliness specifications for working on the auxiliary/sup‐
plementary heater and fuel system”, page 5
3.1 Cleanliness specifications for working

on the auxiliary/supplementary heater
and fuel system
When working on the fuel supply and injection system, observe
the following “6 rules” for cleanliness:
♦ Thoroughly clean all unions and surrounding areas before dis‐
connecting.
♦ Place removed parts on a clean surface and cover. Use only
lint-free cloths.
♦ Carefully cover opened components or seal if repairs cannot
be carried out immediately.
♦ Install clean components only. Do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have not been stored in their packing (e.g. in
tool boxes etc.).
♦ When the system is open: Do not work with compressed air.
Do not move vehicle unless absolutely necessary.
♦ Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.
3. General notes 5
20 – Fuel supply system

1 Procedure when filling with incorrect
fuel
Caution
Irreversible damage to high-pressure components, especially

the high-pressure pump due to lack of lubrication though diesel
can occur when filling fuel tank with incorrect fuel. Damage due
to seizure and metal particles can be expected. These metal
particles will probably cause further damage to pressure reg‐
ulating valves and injectors.
Note

joined.
♦ These instructions are intended to guide you through the in‐
dividual work steps by means of a flowchart, with various
factors being taken into account.
Was the engine started with the incorrect fuel?

Yes
⇒ “1.1 Step 1 (Engine was started with incorrect fuel)”,
page 6
No
⇒ “1.2 Step 2 (Engine was not started with incorrect fuel)”,
page 7
1.1 Step 1 (Engine was started with incor‐

rect fuel)
– Empty fuel tank as far as possible via fuel filler neck using fuel
extractor - VAS 5190- ⇒ page 26 .
– Remove rear bench seat ⇒ General body repairs, interior;
Rep. gr. 72 ; Rear seat; Removing and installing bench seat /
individual seats .
– Remove flange cover of fuel delivery unit.
Note
Press in securing ring to release fuel line.
6 Rep. gr.20 - Fuel supply system

WARNING
The fuel pump can be activated by opening of a door when the

battery is connected! Fuel can escape if the system has been
opened.
– Pull fuel return line (blue line or blue marking) -1- off fuel de‐
livery unit.
– 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 diagnosis tester and then carry out guided
function “Fuel pump activation (Emptying fuel system)”.
Note
The fuel pump will now be activated.
– Repeat procedure, if necessary, until fuel tank is completely

empty.
Remove fuel delivery unit ⇒ page 36 .
– Check fuel tank for filings.
– Drain fuel pump reservoir of fuel delivery unit.
– Carry out a visual inspection for foreign bodies and filings in
fuel pump reservoir and on preliminary filter.
Filings found?
Yes
⇒ “1.3 Step 3 (There are filings in fuel delivery unit and fuel
tank)”, page 8
No
⇒ “1.4 Step 4 (There are no filings in fuel delivery unit and fuel
tank)”, page 9
1.2 Step 2 (Engine was not started with in‐

correct fuel)
– Empty fuel tank as far as possible via fuel filler neck using fuel
extractor - VAS 5190- ⇒ page 26 .
Rep. gr. 72 ; Rear seat; Removing and installing bench seat /
individual seats .
– Remove flange cover of fuel delivery unit.
Note
1. Procedure when filling with incorrect fuel 7

WARNING
The fuel pump can be activated by opening a door when the

battery is connected. Fuel can escape if the system has been
opened.
– Pull fuel return line (blue line or blue marking) -1- off fuel de‐
livery unit.
– 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 diagnosis tester and then carry out guided
function “Fuel pump activation”.
Note
The fuel pump will now be activated.
– Repeat procedure, if necessary, until fuel tank is completely

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

– Replace fuel filter ⇒ page 50 .
– Fill up vehicle and perform road test.
End
1.3 Step 3 (There are filings in fuel delivery

unit and fuel tank)
– Clean fuel delivery unit and fuel tank with diesel extractor -
VAS 5226- .
– Install fuel delivery unit ⇒ page 36 .
For vehicles with auxiliary/supplementary heater
– Check fuel line between fuel tank and metering pump - V54-
for shavings. If necessary, renew both ⇒ Rep. gr. 82 ; Fuel
supply; Removing and installing metering pump .
Continuation 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/high-pressure

accumulator (fuel rail): Removing and installing high-pressure
lines .
♦ High-pressure accumulator (fuel rail) including fuel pressure
regulating valve - N 276- and fuel pressure sender - G 247- ⇒
Rep. gr. 23 ; Injectors/high-pressure accumulator (fuel rail):
Removing and installing high-pressure accumulator .
♦ Injector ⇒ Rep. gr. 23 ; Injectors/high-pressure accumulator
(fuel rail): Removing and installing injectors .
♦ Fuel return lines (leakage oil lines) ⇒ Rep. gr. 23 ; Injection
system; Assembly overview - fuel system
♦ Replace fuel filter ⇒ page 50 .
– Fill up vehicle.
– Bleed fuel system ⇒ Rep. gr. 23 ; Injection system; Filling/
bleeding fuel system .
– Perform road test.
End
1.4 Step 4 (There are no filings in fuel deliv‐

ery unit and fuel tank)
Caution
When the fuel metering valve - N290- is removed, there is the

risk of damage to the high-pressure pump by the ingress of dirt
from the outside. Scrupulous cleanliness must therefore be
ensured.
– Carefully clean high-pressure pump in vicinity of fuel metering

valve - N290- .
– Detach connector from valve.
– Unscrew bolts -arrows- and carefully remove fuel metering
valve - N290- .
Vehicles with engine code CBAA, CBAB, CBBB, CBAC, CBDC

Vehicles with engine code CAYC

– Check fuel metering valve - N290- and high-pressure pump
for metal particles.
Filings found?
Yes
⇒ “1.5 Step 5 (There are filings in high-pressure pump)”, page
10
No
⇒ “1.6 Step 6 (There are no filings in high-pressure pump)”,
page 10
1.5 Step 5 (There are filings in high-pres‐

sure pump)
– 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/high-pressure
accumulator (fuel rail): Removing and installing high-pressure
lines .
♦ High-pressure accumulator (fuel rail) including fuel pressure
regulating valve - N 276- and fuel pressure sender - G 247- ⇒
Rep. gr. 23 ; Injectors/high-pressure accumulator (fuel rail):
Removing and installing high-pressure accumulator .
♦ Injector ⇒ Rep. gr. 23 ; Injectors/high-pressure accumulator
(fuel rail): Removing and installing injectors .
♦ Fuel return lines (leakage oil lines) ⇒ Rep. gr. 23 ; Injection
system; Assembly overview - fuel system
♦ Replace fuel filter ⇒ page 50 .
– Fill up vehicle.
– Perform road test.
End
1.6 Step 6 (There are no filings in high-pres‐

sure pump)
Caution
Ensure that the oil seals of the fuel metering valve - N290- are
undamaged. If a seal is damaged, the high-pressure pump
must be renewed.
– Moisten lower seal of fuel metering valve - N290- with fuel.

– Slide valve into high-pressure pump while turning slightly.

– Screw in both bolts -arrows- finger-tight.

Vehicles with engine code CBAA, CBAB, CBBB, CBAC, CBDC
Models with engine codes CAYB, CAYC

– Tighten bolts initially to 3 Nm, then tighten further to 7 Nm.
– Replace fuel filter ⇒ page 50 .
– Fill up vehicle and perform road test.
End

2 Fuel tank
⇒ “2 Safety instructions”, page 2
⇒ “2.1 Assembly overview - fuel tank”, page 12
⇒ “2.2 Removing and installing fuel tank”, page 17
⇒ “2.3 Emptying fuel tank”, page 26
2.1 Assembly overview - fuel tank

⇒ “2.1.1 Assembly overview - fuel tank, vehicles with front-wheel
drive”, page 12
⇒ “2.1.2 Assembly overview - fuel tank, vehicles with four-wheel
drive”, page 15
2.1.1 Assembly overview - fuel tank, vehicles with front-wheel drive
Note
♦ Plug-in connectors for fuel lines must engage »audibly« when joined.
♦ Take note of colour assignment when installing the plug-in connectors ⇒ page 43
♦ Hose connections are secured with either spring-type or clamp-type clips.
♦ Renew clamp-type clips with spring-type clips.
♦ Spring-type clip pliers - VAS 5024/- or hose clip pliers - V.A.G 1921/- are recommended for installation of
spring-type clips.

1 - Cap
2 - 1.5 Nm
3 - Tank flap unit
❑ With rubber cup.
❑ Removing and installing
⇒ General body repairs,
exterior; Rep. gr. 55 ;
Tank flap unit; Remov‐
ing and installing fuel
tank flap unit
4 - Earth connection
❑ Ensure secure seating
5 - Elbow
6 - 10 Nm
7 - Fuel tank
❑ When removing, sup‐
port using engine and
gearbox jack - V.A.G
1383 A- .
⇒ page 17
❑ Emptying fuel tank
⇒ page 26 .
8 - Securing strap
❑ Note installation posi‐
tion
9 - Heat shield
❑ For fuel tank.
10 - Lock washer, 2.5 Nm
11 - 25 Nm
❑ Renew
Note
To secure the securing straps for

the fuel tank, only bolts with loose
washers must be used. If different
bolts are used, the securing straps
might twist during tightening.
12 - Metering pump - V54-

if fitted
For auxiliary/supplementary heater

❑ Removing and installing ⇒ Heating, air conditioning; Rep. gr. 82 ; Fuel supply; Removing and installing
metering pump
13 - Seal
❑ Renew
❑ When installing, fit dry in fuel tank opening.
❑ Moisten with fuel only when installing flange.
14 - Fuel delivery unit
❑ With fuel system pressurisation pump - G6- and fuel gauge sender.
❑ Removing and installing ⇒ page 36
2. Fuel tank 13
❑ Checking fuel pump ⇒ page 58 .
❑ Removing and installing fuel gauge sender ⇒ page 39 .
15 - Suction-jet pump
❑ Clean strainer if soiled.
❑ Not always installed
16 - Flange
❑ For fuel delivery unit
❑ Note installation position of flange on fuel tank ⇒ page 14 .
17 - Locking ring, 110 Nm
❑ Remove and install using wrench - 3087-
18 - Supply line
if fitted
❑ For auxiliary/supplementary heater
❑ To metering pump - V54- .
❑ Clipped onto fuel tank.
❑ To pull off flange, press release button on connecting piece.
19 - Return line
❑ Blue or with blue marking.
20 - Supply line
❑ To fuel filter
❑ Black
Installation position of fuel delivery unit

Marking -4- on flange points opposite direction of travel.
Note
The fuel delivery unit flange can be installed only in this position.
Connect black supply line -1- with arrow to union on flange.

Return line -2- (blue or with blue marking) to connection marked
“R”.
Black supply line -3- to metering pump - V54- for auxiliary/sup‐
plementary heater (if fitted).
Note
After installing fuel delivery unit flange, check that fuel lines are
still clipped onto fuel tank.

2.1.2 Assembly overview - fuel tank, vehicles with four-wheel drive
Note
♦ Plug-in connectors for fuel lines must engage »audibly« when joined.
♦ Take note of colour assignment when installing the plug-in connectors ⇒ page 43
♦ Hose connections are secured with either spring-type or clamp-type clips.
♦ Renew clamp-type clips with spring-type clips.
♦ Spring-type clip pliers - VAS 5024/- or hose clip pliers - V.A.G 1921/- are recommended for installation of
spring-type clips.
1 - Supply line
2 - Locking ring, 110 Nm
❑ Remove and install us‐
ing wrench - T10202-
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 - 10 Nm
7 - Earth connection
8 - Pressure retention valve
with connecting hose
❑ To remove, grasp se‐
curing ring (grey) and
pull off upwards.
9 - Breather line
10 - Suction-jet pump
❑ Clipped onto fuel gauge sender 2 - G169-
11 - 25 Nm
❑ Renew
2. Fuel tank 15
Note
To secure the securing straps for

the fuel tank, only bolts with loose
washers must be used. If different
bolts are used, the securing straps
might twist during tightening.
12 - Seal
❑ Renew
❑ When installing, fit dry in fuel tank opening.
❑ Moisten with fuel only when installing flange.
13 - Fuel gauge sender 2 - G169-
❑ Note installation position on fuel tank ⇒ page 16
14 - Fuel tank
❑ Emptying ⇒ page 26
15 - Heat shield
❑ Bolted with clamping washers.
16 - 25 Nm
❑ Renew
❑ Securing bolt of tensioning strap, heat shield and mounting for middle silencer. Secure support for centre
silencer to body.
17 - Securing strap
18 - Breather line
19 - Fuel delivery unit
❑ With fuel gauge sender - G- .
❑ Removing and installing fuel gauge sender - G- ⇒ page 39 .
❑ Clean strainer if soiled.
20 - Flange with fuel filter
❑ With 6-bar pressure limiting valve.
❑ Note installation position on fuel tank ⇒ page 16
❑ Removing and installing.
Installation position of flange for fuel delivery unit and fuel gauge
sender 2 - G169-
The marking on the flange must align with the marking on the fuel
tank -arrow-.
Note
The marking on the fuel tank is not clearly visible.
A - Flange for fuel delivery unit

B - Flange for fuel gauge sender 2 - G169-

2.2 Removing and installing fuel tank

⇒ “2.2.1 Removing and installing fuel tank - vehicles with front-
wheel drive”, page 17
⇒ “2.2.2 Removing and installing fuel tank - vehicles with four-
2.2.1 Removing and installing fuel tank - ve‐

hicles with front-wheel drive
Special tools and workshop equipment required
♦ Torque wrench (5... 50 Nm) - V.A.G 1331-
♦ Engine and gearbox jack - V.A.G 1383/A-
»Carry out the following work sequence«

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

♦ Before disconnecting battery, open fuel tank flap and if nec‐
essary remove wheel bolt lock adapter from luggage compart‐
ment.
– Always follow safety precautions ⇒ page 2 .

Observe rules for cleanliness ⇒ page 5 .
Note
♦ Read-out the anti-theft radio code as the earth strap of the

battery has to be disconnected during the next work steps.
♦ When lowering fuel tank, guide it carefully to prevent damage.
2. Fuel tank 17
– With the ignition switched off, disconnect battery earth strap.

Rep. gr. 72 ; Rear seats; Removing and installing bench seat /
individual seats .
– Remove cover from fuel delivery unit.
– Pull 5-pin connector -5- off fuel delivery unit flange.
– Open fuel tank filler flap.
– Unscrew securing bolt and remove tank flap unit with rubber
cup ⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap
unit; Removing and installing tank flap unit .
– Empty fuel tank ⇒ page 26 .
– Remove right rear wheel.
– Remove rear right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liner; Removing
and installing wheel housing liner .
– Remove bolts from filler neck -arrows-.
– Unclip ABS sensor wire on filler neck -arrows-.

– Remove underbody panel between rear axle and underbody
panels at side ⇒ General body repairs, exterior; Rep. gr. 66 ;
Underbody panel; Removing and installing underbody panels .
– Remove rear axle cladding.
WARNING
♦ The fuel and the fuel lines in the fuel system can become
very hot (danger of scalding)!
♦ The fuel system is also under pressure!
♦ Before opening the system place a cloth around the con‐
nection.
♦ Release pressure by carefully loosening the connection.
♦ Wear eye and hand protection when performing any type
of repair work on the fuel system!

– Separate return line -1- and supply line -2- at connections.

– Disconnect fuel line -3- for metering pump - V54- at connection
(if fitted).
Note
Press in securing ring to release fuel lines.
– Pull connector -arrow- off metering pump - V54- (if fitted).
Note
Disconnect headlight range control connector, if there is one.
– Position engine and gearbox jack - V.A.G 1383 A- with uni‐

versal gearbox support - V.A.G 1359/2- under final drive and
secure using tensioning belt.
– Remove a hexagon head bolt -1- or -2- on each side.
Note
For greater clarity, only the left side of the vehicle is shown.
To fix the location of the rear axle, locating pins - T10096- must
be screwed in one at a time at positions -1- and -2- on both sides
of the vehicle.
2. Fuel tank 19
– Fix the position of rear axle using locating pins - T10096- .
Note
Locating pins - T10096- may be tightened only to max. 20 Nm or

the thread of the locating pin will be damaged.
– Replace subframe securing bolts one at a time on both sides

with locating pins - T10096- and tighten them to 20 Nm.
The position of the rear axle is now fixed.
– Carefully lower rear axle.
– Then support fuel tank using engine and gearbox jack - V.A.G
1383 A- .
– Remove securing strap bolts.

– Slowly lower fuel tank. Whilst doing so, pull fuel tank forwards
and turn it.
– Guide filler neck between rear axle and body.
Installing
Note

joined.
Install in reverse order. In the process, note the following:

– Tighten bolts of rear axle to body ⇒ Running gear, axles,
steering; Rep. gr. 42 ; Rear axle; Overview - rear axle .
♦ Fuel lines are to be installed free of kinks.
♦ Do not interchange supply line and return line (return line blue
or with blue marking, supply line black).
♦ Ensure that line connections are tight.
♦ Connections for fuel lines must engage audibly when joined.
♦ Check earth connection between body and filler neck for prop‐
er seating.
♦ Clip fuel lines onto fuel tank.
2.2.2 Removing and installing fuel tank - ve‐

hicles with four-wheel drive

♦ Torque wrench (5 … 50 Nm) - V.A.G 1331-
♦ Engine and gearbox jack - V.A.G 1383 A-
Removing
Note
♦ The rear axle must be removed to remove the fuel tank.

♦ Always follow safety precautions ⇒ page 2 .
♦ Observe rules for cleanliness ⇒ page 5 .
♦ Assembly overview - fuel tank ⇒ page 15 .
– If necessary, empty fuel tank using fuel extractor - VAS 5190-

⇒ page 26 .
– Remove bench seat ⇒ General body repairs, interior; Rep. gr.
72 ; Rear seats; Removing and installing bench seat / individ‐
ual seats .
– Pull 5-pin connector -arrow- off flange.
Note
For vehicles with auxiliary heater the metering pump - V54- con‐
nector must be separated additionally.
2. Fuel tank 21
– Disconnect connector to four-wheel drive control unit - J492-

-arrow-.
– Unclip sealing grommet -1- downwards out of cover and guide
electric wiring harness of four-wheel drive control unit - J492-
out downwards.
– Remove cover -1- and pull 3-pin connector -arrow- off flange.
– Remove rear right wheel.
– Remove rear right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liner; Removing
and installing wheel housing liner .
– Unclip electrical wire on filler neck.

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

– Remove front left and right underbody panels from underbody.

– Separate return line -1- and supply line -2- at connections.

– Pull connector -arrow- off metering pump - V54- .
– Remove tunnel bridge from underbody -arrows-.

– Remove heat shields under propshaft.
– Remove rear propshaft tube ⇒ Final drive; Rep. gr. 39 ; Over‐
view - repairing propshaft .
– Remove heat shield under fuel tank.
WARNING
Fuel supply line is pressurised. Wear eye protection and pro‐

tective clothing to avoid possible injury and skin contact. Before
nection.
– Separate breather line (white) -1- and fuel line (black) -2- at
connections.
Note
♦ Press in securing ring to release fuel line.

♦ Vehicles with auxiliary heater, the fuel line of the metering
pump - V54- must also be separated.
– Unclip brake lines -arrow- on left from body.
2. Fuel tank 23
– Position engine and gearbox jack - V.A.G 1383 A- with uni‐

versal gearbox support - V.A.G 1359/2- under final drive and
secure using tensioning belt.
– Remove a hexagon head bolt -1- or -2- on each side.
Note
For greater clarity, only the left side of the vehicle is shown.
To fix the location of the rear axle, locating pins - T10096- must
be screwed in one at a time at positions -1- and -2- on both sides
of the vehicle.
– Fix the position of rear axle using locating pins - T10096- .
Note
Locating pins - T10096- may be tightened only to max. 20 Nm or

the thread of the locating pin will be damaged.
– Replace subframe securing bolts one at a time on both sides

with locating pins - T10096- and tighten them to 20 Nm.
The position of the rear axle is now fixed.
– Carefully lower rear axle.
– Support fuel tank using engine and gearbox jack - V.A.G 1383
A- .

– Unscrew securing bolts for securing straps and fuel tank

-arrows-.
– Slowly lower fuel tank and unclip wiring on fuel tank from four-
wheel drive control unit - J492- .
Note
The filler neck must be “guided out” between body and rear axle.
To do this, take the fuel tank off engine and gearbox jack - V.A.G
1383 A- with the assistance of a 2nd mechanic.
Installing
Note

joined.
– With the aid of a 2nd mechanic, guide the filler neck in between
rear axle and body. Then place the fuel tank on the engine and
gearbox jack - V.A.G 1383 A- .
– Clip in wiring on fuel tank for four-wheel drive control unit -

J492- -arrows-.
– Raise fuel tank slowly up to installation position and secure it

in place.
– Reaffix rear axle to body ⇒ Running gear, axles, steering;
Rep. gr. 42 ; Rear axle; Overview - rear axle .
The remaining installation steps are carried out in the reverse se‐
quence. In the process, note the following:
2. Fuel tank 25
– Observe installation position of covers -arrows-:

The -arrows- on the covers point forwards.
A - Cover for fuel delivery unit
B - Cover for fuel gauge sender 2 - G169-
♦ Install breather and fuel lines free of kinks.
♦ Check earth connection on fuel tank and body to filler neck.
Specified torques:
Component Nm
Fuel tank to body 251)
Tunnel bridge to underbody 23
Filler neck to body 10
1) Renew.
2.3 Emptying fuel tank

⇒ “2.3.1 Emptying fuel tank when fuel pump is intact”,
page 26
⇒ “2.3.2 Emptying fuel tank if it is more than 3/4 full”, page 29
⇒ “2.3.3 Emptying fuel tank less than 3/4 full, vehicles with front-
⇒ “2.3.4 Emptying fuel tank less than 3/4 full, vehicles with four-
2.3.1 Emptying fuel tank when fuel pump is intact

Special tools and workshop

equipment required
♦ Wrench - T10202-
♦ Torque wrench - V.A.G
1332-
♦ Fuel extractor - VAS 5190-
♦ Vehicle diagnosis tester.

♦ Adapter for fuel extraction - VAS 5190 /2-
2. Fuel tank 27
Note
If the fuel extraction unit - VAS 5190- is still fitted with an extraction
hose with a fixed tip, the extraction hose must be replaced with
the version with a screwed tip.
WARNING

nection.
– Pull off supply line -arrow- and catch escaping fuel with a cloth.
Note
– Connect fuel extractor - VAS 5190- with adapter for fuel ex‐
tractor - VAS 5190 /3 - to fuel supply line.

– Separate connector -A- to supplementary fuel pump - V393-

or fuel pump 2 - V277- (inline electronic fuel pump).
– Connect vehicle diagnosis tester.
– Switch on ignition.
– Remove filler cap from fuel tank filler neck.
– Connect vehicle diagnosis tester and perform the guided func‐
tion “Emptying fuel system”.
Note
The fuel pumps are now actuated. The vehicle diagnosis tester
shows the progress of the drainage.
– Open shut-off tap on fuel extractor - VAS 5190- until fuel tank
is emptied.
Note

joined.
2.3.2 Emptying fuel tank if it is more than 3/4

full
♦ Fuel extractor - VAS 5190 A- for E 85 fuel (not shown).
Caution
Secure earth wire of fuel extractor - VAS 5190- to a bare metal

part of the body.
2. Fuel tank 29
– Remove cotter -2- from shaft -1- of fuel extractor - VAS 5190- .
– At a distance of -a- from the end of the hose, mark extraction
hose with insulating tape -arrow-.
Distance -a-
Motorkennbuchstabe CAYC - 1200 mm
Motorkennbuchstaben CBAA, CBAB, CBAC, CBBB, CBDC - 990
mm
– Remove filler cap from fuel tank filler neck.

– Screw shaft end -1- of fuel extractor unit - VAS 5190- onto fuel
filler neck.
– Push extraction hose into fuel tank until marking on hose
-arrow- coincides with shaft end.
Note
A ball valve -2- is located at the bottom of the filler neck in the fuel
tank -1-; it must not be damaged by the extraction hose -3-.
Therefore push hose into filler neck only as far as marking
-arrow-.
– Drain fuel tank as much as possible through fuel filler neck.

– Carefully pull out extraction hose.
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.
♦ If work must be performed on fuel pump or fuel tank sender,
proceed as follows:
2.3.3 Emptying fuel tank less than 3/4 full, vehicles with front-wheel drive


equipment required
♦ Removal wedge - 3409-
♦ Wrench - T10202-
1332-

ual seats .
WARNING

nection.
2. Fuel tank 31
– First check that the connector -arrow- is fitted securely by pull‐

ing the connector without pressing the catch. The connector
can cause a fault if it has not been fitted correctly.
– Now pull off connector.
– Pull fuel lines off flange.
Note
– Open locking ring using fuel tank sender wrench - T10202- .

– Lift sender flange.
– Insert extraction hose of fuel extractor - VAS 5190- as deeply
as possible into fuel tank and extract fuel.
If fuel tank needed only to be emptied, reinstall sender flange.
Note

joined.
2.3.4 Emptying fuel tank less than 3/4 full, vehicles with four-wheel drive


equipment required
♦ Removal wedge - 3409-
♦ Wrench - T10202-
1332-

ual seats .
Note
To drain fuel tank completely: fuel must be extracted from fuel

delivery unit flange and also from fuel pump sender 2 - G169-
flange.
Draining fuel tank at fuel delivery unit flange ⇒ page 33 .

Draining fuel tank at fuel gauge sender 2 - G169- flange
⇒ page 34 .
Draining fuel tank at fuel delivery unit flange:
2. Fuel tank 33
WARNING

nection.
– Pull 5-pin connector -A- and fuel line -B- off flange.
Note
♦ Press in securing ring to release fuel line.

♦ On vehicles with auxiliary heater the connector and the fuel
line of the metering pump - V54- must also be separated.
– Open locking ring using wrench - T10202- .

– Lift flange.
– Drain fuel tank at fuel gauge sender 2 - G169- flange
⇒ page 34 .
Draining fuel tank at fuel gauge sender 2 - G169- flange

-arrow-.
out downwards.


– Lift flange.
If fuel tank needed only to be emptied, install flanges with covers
again ⇒ page 35 .
Installing flanges with covers:
Installation is performed in the reverse sequence. In the process,
note the following:
♦ Moisten seal with fuel only when installing flange.
– Observe installation position of flanges -arrows-:

tank -arrows-.
Note
A - Flange for fuel delivery unit

– Tighten locking ring using wrench - T10202- . Specified torque:
110 Nm.
– Observe installation position of covers -arrows-:

The -arrows- on the covers point forwards.
A - Cover for fuel delivery unit
Note

joined.
2. Fuel tank 35
3 Fuel delivery unit and fuel gauge

sender
⇒ “3.1 Removing and installing fuel delivery unit, fuel gauge send‐
er”, page 36
⇒ “3.2 Removing and installing fuel gauge sender”, page 39
3.1 Removing and installing fuel delivery

unit, fuel gauge sender
♦ Wrench - T10202-
♦ Torque wrench (40... 200 Nm) - V.A.G 1332-

Removing
– Always follow safety precautions ⇒ page 2 .
Observe rules for cleanliness ⇒ page 5 .
– First check whether a coded radio is fitted. If so, obtain anti-
theft coding.
– With the ignition switched off, disconnect battery earth strap.
– The fuel tank must not be more than 1/2 full when removing
the suction-jet pump. Empty fuel tank if necessary
⇒ page 26 .
individual seats .

– Pull supply line -1-, return line -2-, and if fitted supply line -3-
to metering pump - V54- and 5-pin connector -5- off fuel
delivery unit flange.
Note

– Lift sender flange.
3. Fuel delivery unit and fuel gauge sender 37

– Pull fuel line -1- off suction-jet pump (if fitted).
Note
– Press tab -2- of suction-jet pump in -direction of arrow- and

unclip from fuel delivery unit
– Pull fuel delivery unit along with suction-jet pump out of open‐
ing in fuel tank.
Note
If delivery unit is to be renewed, drain old delivery unit before dis‐

posal.
Installing
Note

joined.
– Installing the fuel delivery unit is carried out in reverse order

of removal.
Note
♦ For fuel delivery units of the new generation the suction jet
pump is no longer available. If the fuel delivery unit is to be
renewed, remove suction jet pump.
♦ When inserting fuel delivery unit, ensure that fuel gauge send‐
er is not bent.
♦ Insert seal for flange or fuel delivery unit dry into opening of
fuel tank.
♦ Moisten seal with fuel only when installing flange or fuel de‐
livery unit.
♦ Do not interchange supply line and return line (return line blue
or with blue marking, supply line black).
♦ Ensure that fuel hose connections are tight.
♦ Connections for fuel lines must engage audibly when joined.
♦ After installing fuel delivery unit, check that fuel lines are still
clipped onto fuel tank.
♦ Observe installation position of fuel delivery unit ⇒ page 14 .

3.2 Removing and installing fuel gauge

sender
⇒ “3.2.1 Removing and installing fuel gauge sender G ”,
page 39
⇒ “3.2.2 Removing and installing fuel gauge sender 2 G169 ”,
page 40
3.2.1 Removing and installing fuel gauge

sender - G -
Removing (old version)
– Remove fuel delivery unit ⇒ page 36 .
– Release connectors -arrows- and pull off connectors
-1, 2 and 3-.
– Raise retaining tabs -4- and -5- using a screwdriver and pull
fuel gauge sender - G- off downwards -arrow-.
Installing
– Insert fuel gauge sender - G- into guides on fuel delivery unit
and press upwards until it engages.
– Reconnect connector and check that it has engaged correctly.
– Pull fuel gauge sender - G- slightly to side and upwards at the

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

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

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

bend back locking devices of connector.
Installing
– Connect connectors -1…3-. Observe colour co-ordination.

– Check connectors are secured properly by pulling.
– Insert fuel gauge sender - G- into guide on fuel delivery unit
and press down until it engages.
3.2.2 Removing and installing fuel gauge

sender 2 - G169-
♦ Wrench - T10202-

Removing
Prerequisites:
• Fuel tank must not be more than 1/2 full.
Note

♦ Ensure float arm of fuel gauge sender 2 - G169- is not bent.
– If necessary, empty fuel tank using fuel extractor - VAS 5190-

⇒ page 26 .
ual seats .
-arrow-.
out downwards.

– Pull fuel gauge sender 2 - G169- upwards slightly and unclip

locking lugs -arrows- of suction-jet pump.
Installing
Caution
When installing do not bend fuel gauge sender 2 - G169- float

arm.
– Place fuel gauge sender 2 - G169- in fuel tank.
– Fit suction-jet pump on sender on inside of fuel tank. Locking

lugs of suction-jet pump -arrows- must engage.
The remaining installation steps are carried out in the reverse se‐
quence. In the process, note the following:
♦ Moisten seal with fuel only when installing flange.
– Observe installation position of flange -B-:

tank -arrow-.
Note

– Tighten locking ring using wrench - T10202- . Specified torque:
110 Nm.
– Observe installation position of cover -B-:

The -arrow- on the cover points forwards.

4 Separating plug-in connectors

♦ Lever - T10468-
Assignment of plug-in connectors
Note
♦ The plug-in connectors for fuel, vacuum and breather lines are
colour coded. There is either a coloured dot on the plug-in
connector or the release button is coloured.
joined.
Plug-in connector Colour code on plug-in connec‐

tor
Fuel supply Black
Fuel return line Blue
Breather white, beige
Vacuum Green
WARNING

tective clothing to avoid eye injuries and skin contact. Before
nection.
Variant 1
Plug-in connector with release buttons -arrows- on right and left
4. Separating plug-in connectors 43

Opening
It is necessary to counterhold the separating point for fuel -1- in
the engine compartment.
– Insert lever between heat shield and stop - T10468- -arrow- of
fuel line -2- and counterhold.
Continuation for all separating points of the fuel system

– Push plug-in connector -1- in -direction of arrow A-.
– Press and hold release buttons.
– Pull plug-in connector -1- off fuel line -2- in
-direction of arrow B-.
Take note of colour assignment during installation ⇒ page 43
Plug-in connectors for fuel lines must engage »audibly« when
joined.
– Ensure plug-in connector is secured properly by pulling it.
Variant 2
Plug-in connector with pull-release mechanism -arrow-

Opening
– 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.
Variant 3
Plug-in connector with front button -arrow-
Opening
– Press release button -arrow- and pull off plug-in connectors.
joined.
– Ensure plug-in connectors are secured properly by pulling.
Variant 4
Opening
– Push plug-in connector in -direction of arrow A-.
– Press release buttons -arrows- and pull off plug-in connector.
joined.
Variant 5
Opening
– Press release buttons -arrows- and pull off plug-in connector.
joined.
4. Separating plug-in connectors 45

Variant 6
Opening
– Push plug-in connector in -direction of arrow-.
– Press and hold release buttons -arrows-.
– Pull off plug-in connector
joined.

5 Fuel filter
⇒ “5.1 Assembly overview - fuel filter”, page 47
⇒ “5.2 Removing and installing fuel filter”, page 48
5.1 Assembly overview - fuel filter

⇒ “5.1.1 Assembly overview - fuel filter”, page 47
⇒ “5.1.2 Assembly overview - upper part of fuel filter”, page 48
5.1.1 Assembly overview - fuel filter
1 - Fuel line
❑ Connection overview
⇒ page 48 .
2 - 5 Nm
3 - Washer
4 - Fuel line
⇒ page 48 .
5 - Fuel line
⇒ page 48 .
6 - Fuel line
⇒ page 48 .
7 - Upper part of fuel filter
❑ Note that there are dif‐
ferent versions
⇒ page 48
⇒ page 48 .
⇒ page 50
8 - Filter insert
❑ Renewing ⇒ Mainte‐
nance ; Booklet 26.1 ;
Description of proce‐
dure; Fuel filter: renew‐
ing .
9 - Lower part of fuel filter
10 - 10 Nm
11 - Seal
❑ Renew ⇒ page 50
5. Fuel filter 47
5.1.2 Assembly overview - upper part of fuel

filter
Type A ⇒ page 48
Type B ⇒ page 48
Fuel filter upper part, type A
1 - 8 Nm
2 - (Not necessarily installed) plug for water extraction (remove
and extract about 100 cm3 liquid using hand-operated vacuum
pump with accessories - V.A.G 1390- and water drainage con‐
tainer - V.A.G 1390/1- , renew seal).
3 - Fuel supply line from fuel tank, white or white marking. Check
for secure seating.
4 - Fuel return line to fuel tank, blue or blue marking. Check for
secure seating.
5 - Fuel supply line to engine, white or white marking. Check for
secure seating.
6 - Fuel return line from engine, blue or blue marking. Check for
secure seating.
Fuel filter upper part, type B

1 - 5 Nm
2 - Fuel return line to fuel tank, blue or blue marking. Check for
secure seating.
3 - Fuel supply line from fuel tank, white or white marking. Check
for secure seating.
4 - Fuel return line from engine, blue or blue marking. Check for
secure seating.
5 - Fuel supply line to engine, white or white marking. Check for
secure seating.
5.2 Removing and installing fuel filter

⇒ “5.2.1 Removing and installing fuel filter, engine code CAYC”,
page 48
⇒ “5.2.2 Removing and installing fuel filters, engine codes CBAA,
CBAB, CBBB, CBAC, CBDC”, page 50
⇒ “5.2.3 Removing and installing upper part of fuel filter”,
page 50
5.2.1 Removing and installing fuel filter, en‐

gine code CAYC

Removing
– Open plug-in connectors -A- and -B- of fuel lines.
– Disconnect electrical connector -1- at fuel temperature sender

- G81- .
– Open clips -2+4- and pull off fuel hoses.
– Unclip retainer for coolant hose -1- by pushing it to one side.

– Remove securing bolts ⇒ Item 10 (page 47) .
– Remove fuel filter upwards.
Installing
♦ Route fuel hoses without kinking.
♦ 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).
♦ Clip fuel and coolant hoses into retainers again.
– Bleed fuel system ⇒ Rep. gr. 23 ; Injector unit; Filling/bleeding
fuel system .
5. Fuel filter 49
5.2.2 Removing and installing fuel filters, en‐

gine codes CBAA, CBAB, CBBB,
CBAC, CBDC
Removing
– Open plug-in connectors -A- and -B- of fuel lines.
– Open clamps and pull fuel hoses ⇒ Item 5 (page 47) (5) and
⇒ Item 6 (page 47) (6) off fuel filter.
– Unclip retainer for coolant hose -1- by pushing it to one side.

– Remove securing bolts ⇒ Item 10 (page 47) .
– Remove fuel filter upwards.
Installing
markings).
♦ Bleed fuel system ⇒ Rep. gr. 23 ; Injection system; Filling/
5.2.3 Removing and installing upper part of

fuel filter
♦ Diesel extractor - VAS 5226-

♦ Special wrench, long reach - VAS 6543-

Removing
Caution
♦ Do not pull fuel hoses off fuel filter cover and do NOT lever
on unions. Levering/pulling leads to leaks and damage to
the upper part of the fuel filter.
♦ Please ensure that no diesel contacts other components
in the engine compartment. If necessary clean immedi‐
ately.
Remove engine cover ⇒ Rep. gr. 10 ; Engine cover; Removing

and installing engine cover .
– Unscrew all bolts -arrows- for upper part of fuel filter and re‐
move upper part of fuel filter.
Note
If upper part of fuel filter is tight or seized, loosen upper part of

fuel filter as follows:
Upper part of fuel filter can be raised using an angled screwdriver

- VAS 6543- in assembly groove -arrow A-.
♦ The size of the assembly groove can vary depending on ver‐
sion of upper part.
– Insert respective end of special wrench, long reach - VAS
6543- into assembly groove -arrow A- and turn special wrench,
long reach - VAS 6543- .
5. Fuel filter 51
This action raises the upper part of the fuel filter.
– Remove seal -2- from upper part of fuel filter -1- by prising seal
out of respective groove -arrow-.
Installing
– Moisten new seal -1- with diesel and insert seal into upper part
of fuel filter -arrows-.
– Insert upper part of fuel filter with seal correctly onto lower part
of fuel filter and press on evenly until the upper part of fuel filter
seats completely.
Caution
Do NOT tighten the bolts for the upper part of the fuel filter until
it lies completely on the lower part.

– Insert all bolts into lower part of fuel filter and tighten hand-
tight.
– Then tighten bolts to specified torque in sequence according
to illustration -arrows- ⇒ Item 2 (page 47) .
5. Fuel filter 53
6 Accelerator mechanism
⇒ “6.1 Assembly overview - accelerator module”, page 54
⇒ “6.2 Removing and installing accelerator module”, page 54
6.1 Assembly overview - accelerator module
1 - Connector
❑ Black, 6-pin.
2 - Accelerator pedal module
❑ With accelerator posi‐
tion sender - G79- and
accelerator position
sender 2 - G185-
❑ Not adjustable
❑ The accelerator position
sender passes the posi‐
tion of the accelerator
on to the engine control
unit.
⇒ page 54
❑ -A-: apertures for re‐
lease tool
3 - 10 Nm
4 - Cap
6.2 Removing and installing accelerator

module

♦ Release tool - T10238-
For right-hand drive:
♦ Release tool - T10240-

Removing
– Remove steering column cover -arrows-.
– Prise out cap -3- using a screwdriver.
– Remove securing bolt -2-.
6. Accelerator mechanism 55
– Release connector -1- and pull it off accelerator module.
– Push release tool - T10238- (for right-hand drive vehicles re‐

lease tool - T10240- ) into intended holes as shown to stop
and remove accelerator module.
Installing
– Reconnect connector -1- to accelerator module -4-. Lock con‐

nector -arrow-.
– Press accelerator module onto securing pins -5-.
– Insert centring pin -6- into hole in underbody.
– Secure accelerator module with bolt -2- and install cap -3-.

– Install steering column trim.
6. Accelerator mechanism 57
7 Fuel pump
⇒ “7.1 Checking fuel pump”, page 58
⇒ “7.2 Removing and installing fuel pump”, page 67
⇒ “7.3 Removing and installing suction-jet pump”, page 69
7.1 Checking fuel pump

First check that connector is fitted securely by pulling connector
without pressing locking mechanism.
⇒ “7.1.1 Checking delivery pressure of the fuel pump, engine co‐
des CBAA, CBAB, CBBB, CBAC, CBDC”, page 58
⇒ “7.1.2 Checking the supplementary fuel pump V393 or Fuel
pump 2 V277 (Inline EKP), engine codes CBAA, CBAB, CBBB,
CBAC, CBDC”, page 60
⇒ “7.1.3 Checking delivery rate of fuel pump , engine code
CAYC”, page 62
⇒ “7.1.4 Checking the fuel pump delivery rate for prepressurisa‐
tion G6 , engine codes CBAA, CBAB, CBBB, CBAC, CBDC”,
page 63
⇒ “7.1.5 Checking voltage supply of fuel system pressurisation
pump ”, page 64
⇒ “7.1.6 Checking current consumption of fuel system pressuri‐
sation pump ”, page 66
7.1.1 Checking delivery pressure of the fuel

pump, engine codes CBAA, CBAB,
CBBB, CBAC, CBDC
♦ Pressure tester - VAS 6551-
♦ Vehicle diagnosis tester
Test prerequisite:
• Fuses must be OK.
• Battery voltage at least 12 V
• All electrical consumers, e.g. lights and rear window heating,
must be switched off.

– Separate plug-in connector -A- (completely black or with black

marking) of fuel supply line.
– Connect pressure tester - VAS 6551- with cables -VAS
6551/1- and -VAS 6551/2- to open ends of fuel supply line.
– Switch on pressure tester - VAS 6551- by pressing On/Off
button.
– Open shut-off taps “A” and “B” of pressure tester and close
shut-off tap “C”.
– Start engine and run at idling speed.
– Close shut-off tap “B” for a maximum of 15 seconds and read
the available pressure on the pressure tester - VAS 6551-
within this time. Specification min. 0.5 bar.
– If the delivery pressure temporarily drops, renew fuel delivery
unit.
If the specifications are attained:
– Renew fuel filter, for engine running problems, to ensure the
fuel filter is not blocked.
If the specifications are not obtained
individual seats .
– Detach carpet under seats and fold it back. ⇒ General body
repairs, interior; Rep. gr. 70 ; Interior trim; Assembly overview
- foot support and floor covering
Note
– Pull fuel supply line (black or black marking) -A- off fuel deliv‐
ery unit.
– Connect pressure tester - VAS 6551- to open ends of fuel
supply pipe and fuel delivery unit using lines -VAS 6551/1- and
-VAS 6551/2- .
– Switch on pressure tester - VAS 6551- by pressing On/Off
button.
– Open shut-off taps “A” and “B” of pressure tester and close
shut-off tap “C”.
– Start engine and run at idling speed.
– Close shut-off tap “B” for a maximum of 15 seconds and read
the available pressure on the pressure tester - VAS 6551-
within this time. Specification min. 0.5 bar.
If the specifications are again not attained:
– Check delivery rate of fuel pump ⇒ page 63 .
Note
After assembling, check all plug-in connectors are engaged cor‐

rectly by pulling on connector.
7. Fuel pump 59
7.1.2 Checking the supplementary fuel pump

- V393- or Fuel pump 2 - V277- (Inline
EKP), engine codes CBAA, CBAB,
CBBB, CBAC, CBDC
Note
The component designation for the inline electronic fuel pump

was changed from “supplementary pump V393” to “fuel pump 2
V277” in a software revision. This is the same component.

♦ K-Jetronic pressure tester - V.A.G 1318-
Test prerequisites
• Battery voltage at least 12.5 V
• Fuel filter OK.
• Fuel tank: level min »reserve«.
• Ignition switched off.
– Remove engine cover ⇒ Rep. gr. 10 ; Engine cover; Remov‐
ing and installing engine cover .
WARNING
♦ Always read rules for cleanliness and instructions for

working on fuel system ⇒ page 5 .
♦ Always follow these rules for cleanliness and instructions
before starting work and while working on the fuel system.
♦ Wrap a clean cloth around the connection before opening
the fuel system. Then release pressure by carefully pulling
hose off connection.

– Pull fuel supply line -arrow- off high-pressure pump.
– Connect K-Jetronic pressure tester - V.A.G 1318- with suitable

adapter -2- to fuel supply line -1-. Connect other adapter -3-
from K-Jetronic pressure tester - V.A.G 1318- to open con‐
nection on high-pressure pump.
Note
The K-Jetronic pressure tester - V.A.G 1318- must be inserted as

an intermediate element into the fuel supply line.
– Connect diagnosis tester and perform the guided function

“Checking electric fuel pump(s)”.
Note
The fuel pump is now actuated for 30 seconds.
– Run fuel pumps until highest fuel pressure has built up.
• Specification: at least 3.5 bar
If the specification is not attained:
Check union between pressure gauge and fuel line for leaks.
Test pressure gauge for leaks.
Check fuel lines and their connections for leaks.
Check whether fuel filter is blocked.
Check fuel delivery rate of fuel system pressurisation pump - G6-
⇒ page 63 .
Note
Check fuel system for leaks.
7. Fuel pump 61
7.1.3 Checking delivery rate of fuel pump , en‐

gine code CAYC
Test prerequisites
• Battery voltage at least 12.5 V
• Fuel filter OK.
• Fuel tank at least 1/2 full.
• Ignition switched off
Checking fuel delivery rate
– Remove engine cover ⇒ Rep. gr. 10 ; Engine cover; Remov‐
ing and installing engine cover .
WARNING
♦ Always read rules for cleanliness and instructions for

working on fuel system ⇒ page 5 .
♦ Always follow these rules for cleanliness and instructions
before starting work and while working on the fuel system.
♦ Wrap a clean cloth around the connection before opening
the fuel system, then carefully loosen the connection to
release the pressure.
– Pull fuel supply line -arrow- off the high-pressure pump.

– Hold fuel supply line -1- in a measuring vessel -3- (extend with
a suitable hose -2-).
– Connect Vehicle diagnosis tester and perform guided function
“Fuel pump activation (Checking fuel pump)”.
– Allow fuel pump to run for 30 seconds and end activation.
• Specified minimum delivery rate in 30 seconds: at least 600
ml
If minimum delivery rate is not reached, check for the following
causes:
♦ 30 seconds not reached
♦ Battery voltage below 12.5 V (connect charger)
♦ Fuel lines have been crushed
♦ Fuel filter is blocked
♦ Fuel pump defective: test ⇒ page 66
Note
Check fuel system for leaks.
7.1.4 Checking the fuel pump delivery rate for

prepressurisation - G6- , engine codes
CBAA, CBAB, CBBB, CBAC, CBDC
♦ Pressure tester - VAS 6551-
♦ Container > 3 litre with measuring scale
Test prerequisite:
– Separate connection -A- from supplementary fuel pump -
V393- or fuel pump 2 - V277- .
7. Fuel pump 63
– Separate plug-in connector -A- (completely black or with black

marking) of fuel supply line.
– Connect -VAS 6551/1- pressure tester cable to fuel supply
-A-.
– Guide open end of line into measuring container.
Note
– After fuel flow, read quantity of fuel delivered on measuring

container. Specification: at least 1000 ml/30 s
– Check fuel supply line between fuel pump and engine com‐
partment for kinks, crushes or damage.
– If necessary, renew defective line and repeat test.
– If it is not kinked, crushed or damaged, remove rear bench
seat ⇒ General body repairs, interior; Rep. gr. 72 ; Rear seats;
Removing and installing bench seat / individual seats .
– Detach carpet under seats and fold it over. ⇒ General body
Note
– Pull fuel supply line (black or black marking) -A- off fuel deliv‐
ery unit.
– Connect -VAS 6551/1- pressure tester cable to fuel supply
-A-.
– Guide open end of line into measuring container.
Note
– After fuel flow, read quantity of fuel delivered on measuring

container. Specification: at least 1000 ml/30 s
– Check voltage supply ⇒ page 64 and current draw
⇒ page 66 of fuel pump.
7.1.5 Checking voltage supply of fuel system

pressurisation pump

♦ Hand-held multimeter - V.A.G 1526D-

♦ Pickup clamp - V.A.G 1526B/2-
♦ Test instrument adapter/DSO (5-pin) - VAS 5565-
Test prerequisites
• The battery voltage must be at least 12 V, if necessary connect
a battery charger.
ual seats .
– Remove cover from fuel delivery unit ⇒ page 36 .
– Switch on ignition. The fuel pump must be heard to run for
about 2 seconds.
– Switch off ignition.
If the fuel pump does not start:
– Pull connector off fuel delivery unit flange.
– Connect test instrument adapter/DSO (5-pin) - VAS 5565- be‐
tween connector and flange.
7. Fuel pump 65
– Connect hand-held multimeter - V.A.G 1526D- to contacts

-1- and -5- of adapter.
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 that electrical wiring between flange and fuel pump is
connected and has continuity.
If no open circuit can be found:
– Renew fuel delivery unit ⇒ page 36 .
7.1.6 Checking current consumption of fuel

system pressurisation pump
♦ Hand-held multimeter - V.A.G 1526D- or pickup clamp - V.A.G
1526B/2-
♦ Test instrument adapter/DSO (5-pin) - VAS 5565-
Note
The battery voltage and the diesel fuel temperature have a great
influence on the current draw of the fuel pump. For this reason
ensure that the battery voltage is at least 12 V whilst checking and
the diesel fuel temperature does not fall to the freezing point.
Test prerequisites
• Diesel fuel temperature above 10 °C
ual seats .
– Remove cover from fuel delivery unit ⇒ page 36 .

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

connector and fuel delivery unit.
– Connect pick-up clamp -A- to red terminal with lettering “pick-
up clamp” for test instrument adapter/DSO (5-pin) - VAS
5565- .
Note
Pickup clamp of hand-held multimeter - V.A.G 1715- can also be

connected to red terminal with lettering “pickup clamp” of test in‐
strument adapter/DSO (5-pin) - VAS 5565- .
– Switch on ignition.
Note
– Read current consumption on hand-held multimeter - V.A.G

1526D- : specification: max. 7.5 amperes.
– If the measured value is not within specifications:
– Renew fuel delivery unit.
♦ Removing and installing fuel delivery unit ⇒ page 36 .
7.2 Removing and installing fuel pump

⇒ “7.2.1 Removing and installing supplementary fuel pump V393
or fuel pump 2 V277 (in-line electronic fuel pump)”, page 67
7.2.1 Removing and installing supplementary

fuel pump - V393- or fuel pump 2 - V277-
(in-line electronic fuel pump)
Note
The component designation for the inline electronic fuel pump

was changed from “supplementary pump V393” to “fuel pump 2
V277” in a software revision. This is the same component.
7. Fuel pump 67
♦ Hose clip pliers - VAS 6340-
♦ Torque wrench - V.A.G 1331-
Removing
– Disconnect connector -1- and remove bolt -2-.
– Remove bracket for exhaust gas pressure sensor 1 - G450-
including sensor by pushing in direction of (normal) travel.
– Disconnect connector -A- and unclip fuel hoses -B- from re‐
tainer.
– Open clamp and pull fuel hose ⇒ Item 6 (page 47) off fuel filter.

– Disconnect connector from fuel temperature sender - G81-

-arrow-, loosen clamp -1- and pull fuel supply line off high-
pressure pump.
– Unscrew bolts -arrows-.

– Remove supplementary fuel pump - V393- or fuel pump 2 -
V277- .
Installing
markings).
♦ Specified torque for bracket for exhaust gas pressure sensor
1 - G450- : 8 Nm
7.3 Removing and installing suction-jet

pump
Note
♦ On vehicles with all-wheel drive, a suction-jet pump must

pump the fuel from the area of fuel gauge sender 2 - G169- to
the fuel pump due to the shape of the fuel tank.
♦ Checking is only necessary if the engine stops due to lack of
fuel, even though the fuel gauge shows that the tank is still 1/4
full.

♦ Wrench - T10202-
7. Fuel pump 69
Removing suction-jet pump
Note

– Disconnect fuel lines -1 and 2- to suction-jet pump, removing

and installing fuel delivery unit.
– Remove fuel gauge sender 2 - G169- ⇒ page 40 .
– Now the suction-jet pump can be pulled out from the side of
the fuel gauge sender 2 - G169- (left side of vehicle).
– Check that the fuel lines on suction-jet pump are fitted securely
and are not damaged.
– Additionally check suction-jet pump for possible soiling.
Installing suction-jet pump
Installation is performed in the reverse sequence. In the process,
note the following:

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Service

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

1.1 Engine number, engine data

2.1 Safety precautions during road tests in

2.2 Safety precautions when working on ve‐

♦ The engine of a vehicle with an activated start/stop system

2 Rep. gr.00 - Technical data

2.3 Safety precautions when working on

When doing any repair work, especially in the engine compart‐

When removing and installing fuel gauge sender or fuel pump

Danger of burning from very hot fuel is possible.

The fuel system is pressurised! Wear eye protection and pro‐

Do not damage fuel hoses in engine compartment.

♦ Plug-in connectors for fuel lines must engage »audibly« when

4 Rep. gr.00 - Technical data

3.1 Cleanliness specifications for working

20 – Fuel supply system

Irreversible damage to high-pressure components, especially

♦ Plug-in connectors for fuel lines must engage »audibly« when

Was the engine started with the incorrect fuel?

1.1 Step 1 (Engine was started with incor‐

Press in securing ring to release fuel line.

6 Rep. gr.20 - Fuel supply system

The fuel pump can be activated by opening of a door when the

The fuel pump will now be activated.

– Repeat procedure, if necessary, until fuel tank is completely

1.2 Step 2 (Engine was not started with in‐

Press in securing ring to release fuel line.

1. Procedure when filling with incorrect fuel 7

The fuel pump can be activated by opening a door when the

The fuel pump will now be activated.

– Repeat procedure, if necessary, until fuel tank is completely

– Reconnect fuel return line (blue or blue marking) -1-.

1.3 Step 3 (There are filings in fuel delivery

8 Rep. gr.20 - Fuel supply system

♦ High-pressure lines ⇒ Rep. gr. 23 ; Injectors/high-pressure

1.4 Step 4 (There are no filings in fuel deliv‐

When the fuel metering valve - N290- is removed, there is the

– Carefully clean high-pressure pump in vicinity of fuel metering

1. Procedure when filling with incorrect fuel 9

Vehicles with engine code CAYC

1.5 Step 5 (There are filings in high-pres‐

1.6 Step 6 (There are no filings in high-pres‐

– Moisten lower seal of fuel metering valve - N290- with fuel.

10 Rep. gr.20 - Fuel supply system

– Screw in both bolts -arrows- finger-tight.

Models with engine codes CAYB, CAYC

1. Procedure when filling with incorrect fuel 11

2.1 Assembly overview - fuel tank

2.1.1 Assembly overview - fuel tank, vehicles with front-wheel drive

12 Rep. gr.20 - Fuel supply system

To secure the securing straps for

12 - Metering pump - V54-

For auxiliary/supplementary heater

Installation position of fuel delivery unit

Connect black supply line -1- with arrow to union on flange.

14 Rep. gr.20 - Fuel supply system

2.1.2 Assembly overview - fuel tank, vehicles with four-wheel drive

To secure the securing straps for

The marking on the fuel tank is not clearly visible.