Service

Workshop Manual
Arteon 2018 ➤ , Passat 2015 ➤ ,
Passat 2019 ➤ , Passat Variant 2015 ➤ ,
Passat Variant 2019 ➤ , Tiguan 2016 ➤ ,
Tiguan RUS 2017 ➤
Fuel supply system - diesel engines
Engine ID
CRG CRL CUA CUP DDA DCX DFC CLH DCZ
A B A A A A A C A
DFE DFG DCY DDM DFG CRF CYK DBG DFH
A A A A B C B A A
DCY DGD DFE DFG CRF CRG CRL CYK DBG
B B B C Z B D C B
DBG CRF DSR
C D B
Edition 10.2019

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.
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Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety measures when 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 instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2 Foreign objects in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.3 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.4 Routing and attachment of lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.5 Fitting radiator and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.6 Adapting learnt value for SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1 Procedure should vehicle be misfueled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1 Step 1, engine was started with incorrect fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Step 2, engine was not started with incorrect fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3 Step 3, there are metal particles in fuel delivery unit and fuel tank . . . . . . . . . . . . . . . . . . 12
1.4 Step 4, there are no metal particles in fuel delivery unit or fuel tank . . . . . . . . . . . . . . . . . . 13
1.5 Step 5, there are metal particles in high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.6 Step 6, there are no metal particles in high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . 14
2 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1 Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.2 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.3 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.4 Removing and installing misfuelling prevention device . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.5 Deactivating misfuelling prevention device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3 Fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.1 Assembly overview - fuel delivery unit/fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.2 Removing and installing fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . 64
3.3 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.4 Removing and installing fuel gauge sender 2 G169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.5 Removing and installing assembly opening cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4 Plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.1 Separating plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5.1 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5.2 Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.3 Fuel hoses in the engine compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.4 Drain water from fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
6 Accelerator pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
6.1 Assembly overview - accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
6.2 Removing and installing accelerator pedal module GX2 . . . . . . . . . . . . . . . . . . . . . . . . . . 93
7 Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
7.1 Checking fuel system pressurisation pump G6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
7.2 Removing and installing suction-jet pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Contents i
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7.3 Removing and installing fuel pump control unit J538 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
7.4 Checking suction-jet pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
8 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
8.1 Removing and installing water separator sender G63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
9 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
9.1 Removing and installing fuel lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
9.2 Removing and installing fuel line for auxiliary/supplementary heater . . . . . . . . . . . . . . . . . . 120

ii Contents
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00 – Technical data
1 Safety information
(VRL013471; Edition 10.2019)
⇒ “1.1 Safety measures when 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 measures when working on fuel supply

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

Danger of fire caused by escaping fuel

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

Observe the fill level of the fuel tank:

♦ Fuel tank must be only partly filled. To find out how much fuel
may remain in the fuel tank, refer to the corresponding work
procedure.
♦ If necessary, drain fuel tank ⇒ page 41 .
♦ Before starting work, the extraction hose of a switched-on ex‐
haust gas extraction system must be laid near to the assembly
opening of the fuel tank.
♦ The exhaust extraction system is used to extract fuel vapours.
♦ 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
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To prevent injuries to persons and destruction of the injection and

glow plug system, the following must be noted:
♦ Always switch off the ignition before connecting or discon‐
necting electrical wiring of injection and glow plug system or
connecting/disconnecting tester cables.
♦ Wash the engine only with the ignition switched off.
♦ Entries are stored in the event memory of the engine control
unit if electrical connectors were disconnected and the engine
was started: Read event memory in Guided functions
⇒ Vehicle diagnostic tester.

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

Risk of injury due to unexpected motor start
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.
– Deactivate start/stop system by switching off the ignition.

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

1.4 Safety precautions when working on 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

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nutes after the ignition is switched off ⇒ Electrical system;

Rep. gr. 27 ; Battery; Disconnecting and connecting battery .

1. Safety information 3
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2 Identification
⇒ “2.1 Engine number/engine data”, page 4

2.1 Engine number/engine data

Codes CLHC CRFC CRGA CRLB CUAA CUPA CYKB
Exhaust emission stand‐ EU 5 EU 4 EU 4 EU 6 EU 6 EU 5 EU 6
ard
Displace‐ l 1.6 2.0 2.0 2.0 2.0 2.0 2.0
ment
Power kW 81 105 130 110 176 135 81
Fuel: acc. to DIN EN DIN EN DIN EN DIN EN DIN EN DIN EN DIN EN
590 590 590 590 590 590 590

Codes DBGA DCXA DCYA DCYB DCZA DDAA DDMA

Exhaust emission stand‐ EU 6 EU 6 EU 6 EU 6 EU 6 EU 6 EU 6
ard
Displace‐ l 2.0 1.6 2.0 2.0 1.6 2.0 2.0
ment
Power kW 110 88 110 81 88 140 140
Fuel: acc. to DIN EN DIN EN DIN EN DIN EN DIN EN DIN EN DIN EN
590 590 590 590 590 590 590

Codes DFCA DFEA DFEB DFGA DFGB DFHA DGDB DFGC

Exhaust emission EU 6 EU 6 EU 6 EU 6 EU 6 EU 6 EU 6 EU 6
standard plus
Displace‐ l 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0
ment
Power kW 140 110 81 110 81 140 85 85
Fuel: acc. to DIN EN DIN EN DIN EN DIN EN DIN EN DIN EN DIN EN DIN EN
590 590 590 590 590 590 590 590

Codes CYKC DBGC CRGB CRFZ CRLD DBGB CRFD DSRB

Exhaust emission EU 5 EU 5 EU 4 EU 4 EU 6 EU 5 EU 4 EU 6
standard plus plus plus plus
Displace‐ l 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0
ment
Power kW 81 110 130 105 81 81 105 110
Fuel: acc. to DIN EN DIN EN DIN EN DIN EN DIN EN DIN EN DIN EN DIN EN
590 590 590 590 590 590 590 590

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

4 Rep. gr.00 - Technical data

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3 General information
⇒ “3.1 Rules for cleanliness when working on auxiliary/supple‐
mentary heater and fuel system”, page 5

3.1 Rules for cleanliness when working on

auxiliary/supplementary heater and fuel
system
When working on the fuel supply and injection system, pay careful
attention to the following rules for cleanliness:
♦ Thoroughly clean all joints and surrounding areas before dis‐
mantling.
♦ Place removed parts on a clean surface and cover them over.
Use lint-free cloths only.
♦ Carefully cover opened components or seal them if repairs
cannot be carried out immediately.
♦ Install clean components only. Do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have been kept unpackaged (for example in
toolboxes).
♦ If system is open, do not work with compressed air. Do not
move 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. Renew fuel hoses damaged by fuel.
♦ Protect disconnected electrical connectors from dirt and water,
and reconnect them only when dry.

3. General information 5
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4 Repair instructions
⇒ “4.1 Rules for cleanliness”, page 6
⇒ “4.2 Foreign objects in engine”, page 6
⇒ “4.3 Contact corrosion”, page 6
⇒ “4.4 Routing and attachment of lines”, page 7
⇒ “4.5 Fitting radiator and condensers”, page 7
⇒ “4.6 Adapting learnt value for SCR system”, page 7

4.1 Rules for cleanliness

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

4.2 Foreign objects in engine

To prevent the ingress of foreign bodies during work on the en‐
gine, seal all open connections. To do this, use suitable plugs
from the engine bung set - VAS 6122- .

4.3 Contact corrosion

Contact corrosion can occur if non-approved fasteners are used
on the vehicle (bolts, nuts, washers etc.).
For this reason, only connecting elements with a special surface
coating have been fitted.
Furthermore, rubber and plastic components as well as adhe‐
sives are made of non-conductive materials.
If there are doubts about the suitability of parts, always use new
parts ⇒ Electronic parts catalogue .
Please note:
♦ Use Genuine parts, because they have been are tested and
compatible with aluminium.
♦ Use Volkswagen parts.
♦ Damage resulting from contact corrosion is not covered by the
warranty.

6 Rep. gr.00 - Technical data

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4.4 Routing and attachment of lines

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

♦ Avoid interchanging and ensure that the original installation

position is restored. To do this, mark the lines for the fuel, vac‐
uum and activated charcoal filter system as well as electrical
wiring before they are removed. Where necessary, make
sketches or take photographs.

4.5 Fitting radiator and condensers

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

4.6 Adapting learnt value for SCR system

The learnt value in the engine control unit must be re-adapted
using the vehicle diagnostic tester, if reducing agent has been
drained or if any of the following components have been renewed:
♦ Reducing agent tank
♦ Pump for reducing agent
♦ Injector for reducing agent
♦ Line for reducing agent
♦ Engine control unit
Reset learnt values ⇒ Vehicle diagnostic tester.
Diagnosis-capable systems

0001 - Engine electronics

0001 - Engine electronics functions

0001 - Adapting learnt values for SCR system

4. Repair instructions 7
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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
Fuel analyser unit - VAS 6774- ⇒ Instruction manual . This ana‐
lyser unit is no substitute for a laboratory test in warranty cases.
Special tools and workshop equipment required
♦ Fuel identification unit - VAS 6774-

Note

These instructions are intended as a guide through the individual

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 8
No
⇒ “1.2 Step 2, engine was not started with incorrect fuel”, page
10

1.1 Step 1, engine was started with incorrect

fuel
Special tools and workshop equipment required

8 Rep. gr.20 - Fuel supply system

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♦ Pressure gauge - VAS 6551-

♦ Adapter set - VAS 6551/5-

♦ Removal wedge - 3409-

♦ Vehicle diagnosis and service information system

– Empty fuel tank as far as possible via fuel filler neck using fuel
extractor - VAS 5190- ⇒ page 42 .
– Remove rear bench seat ⇒ General body repairs, interior;
Rep. gr. 72 ; Rear seats; Removing and installing bench seat /
individual seats .
– Remove cover of assembly opening on right or centre
⇒ page 77 .

Note

Bear in mind that the fuel pump can be activated due to opening
of a door with the battery connected. Fuel can escape if the sys‐
tem has been opened.

1. Procedure should vehicle be misfueled 9

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– Disconnect fuel return line -2- at flange. Separate plug-in con‐

nectors ⇒ page 80 .

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

– Connect hose - VAS 6551/1- of pressure tester (diesel) - VAS

6551- to fuel return line.
– If required, extend hose - VAS 6551/1- using connection fitting
- VAS 6551/5-1- and a commercially available hose.
– Put open end of hose - VAS 6551/1- into suitable receptacle.
– Connect the vehicle diagnostic tester .
– Carry out the guided function Empty fuel tank .

Note

The fuel pump is now activated.

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

empty.
Remove fuel delivery unit ⇒ page 64 .
– 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 12
No
⇒ “1.4 Step 4, there are no metal particles in fuel delivery unit
or fuel tank”, page 13

1.2 Step 2, engine was not started with in‐

correct fuel
Special tools and workshop equipment required

10 Rep. gr.20 - Fuel supply system

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♦ Pressure gauge - VAS 6551-

♦ Adapter set - VAS 6551/5-

♦ Removal wedge - 3409-

♦ Vehicle diagnosis and service information system

– Empty fuel tank as far as possible via fuel filler neck using fuel
extractor - VAS 5190- ⇒ page 42 .
– Remove rear bench seat ⇒ General body repairs, interior;
Rep. gr. 72 ; Rear seats; Removing and installing bench seat /
individual seats .
– Remove cover of assembly opening on right or centre
⇒ page 77 .

Note

Bear in mind that the fuel pump can be activated due to opening
of a door with the battery connected. Fuel can escape if the sys‐
tem has been opened.

1. Procedure should vehicle be misfueled 11

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– Disconnect fuel return line -2- at flange. Separate plug-in con‐

nectors ⇒ page 80 .

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

– Connect hose - VAS 6551/1- of pressure tester (diesel) - VAS

6551- to fuel return line.
– If required, extend hose - VAS 6551/1- using connection fitting
- VAS 6551/5-1- and a commercially available hose.
– Put open end of hose - VAS 6551/1- into suitable receptacle.
– Connect the vehicle diagnostic tester .
– Carry out the guided function Empty fuel tank .

Note

The fuel pump is now 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 -2-.

– Renew fuel filter ⇒ page 84 .
– Fill up vehicle and perform road test.
End

1.3 Step 3, there are metal particles in fuel

delivery unit and fuel tank
Special tools and workshop equipment required

12 Rep. gr.20 - Fuel supply system

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♦ Diesel extractor - VAS 5226-

– Clean fuel delivery unit and fuel tank with diesel extractor -
VAS 5226- .
Install fuel delivery unit ⇒ page 64 .
– Fill fuel tank with 5 litres of diesel fuel.
– Completely empty fuel tank again as described above
⇒ page 8 .
– 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 (fuel rail) including fuel pressure regulating valve -
N276- and fuel pressure sender - G247- ⇒ Rep. gr. 23 ;
Injectors/fuel rail (fuel rail): Removing and installing fuel rail
♦ Injector ⇒ Rep. gr. 23 ; Injectors/fuel rail (fuel rail): Removing
and installing injectors .
♦ Fuel return lines (overflow oil lines) ⇒ Rep. gr. 23 ; Injector
units/fuel rail (fuel rail); Assembly overview - injectors .
♦ Fuel filter ⇒ page 84 .
– Fill up vehicle.
– Bleed fuel system ⇒ Rep. gr. 23 ; Injection system; Filling/
bleeding fuel system .
– Carry out road test.
End

1.4 Step 4, there are no metal particles in

fuel delivery unit or fuel tank
– Fill fuel tank with 5 litres of diesel fuel.
– Completely empty fuel tank again as described above
⇒ page 8 .
– 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. Observe strict rules of cleanliness.
– Carefully clean high-pressure pump in vicinity of fuel metering
valve - N290- .
– Detach connector from valve.

1. Procedure should vehicle be misfueled 13

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– Unscrew bolts -arrows- and carefully remove fuel metering

valve - N290- .
– Check fuel metering valve - N290- and high-pressure pump
for metal particles.
Metal particles found?
Yes
⇒ “1.5 Step 5, there are metal particles in high-pressure
pump”, page 14
No
⇒ “1.6 Step 6, there are no metal particles in high-pressure
pump”, page 14

1.5 Step 5, there are metal particles in high-

pressure 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/fuel rail (fuel rail):
Removing and installing high-pressure lines .
♦ fuel rail (fuel rail) including fuel pressure regulating valve -
N276- and fuel pressure sender - G247- ⇒ Rep. gr. 23 ;
Injectors/fuel rail (fuel rail): Removing and installing fuel rail
♦ Injector ⇒ Rep. gr. 23 ; Injectors/fuel rail (fuel rail): Removing
and installing injectors .
♦ Fuel return lines (overflow oil lines) ⇒ Rep. gr. 23 ; Injector
units/fuel rail (fuel rail); Assembly overview - injectors .
♦ Fuel filter ⇒ page 84 .
– Fill up vehicle.
– Bleed fuel system ⇒ Rep. gr. 23 ; Injection system; Filling/
bleeding fuel system .
– Carry out road test.
End

1.6 Step 6, there are no metal particles in

high-pressure pump

Note

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.

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

– First tighten bolts to 3 Nm, then tighten further to 7 Nm.
– Renew fuel filter ⇒ page 84 .
– Bleed fuel system ⇒ Rep. gr. 23 ; Injection system; Filling/
bleeding fuel system .
– Fill up vehicle and perform road test.
End

1. Procedure should vehicle be misfueled 15

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2 Fuel
⇒ “2.1 Assembly overview - fuel tank”, page 16
⇒ “2.2 Removing and installing fuel tank”, page 21
⇒ “2.3 Emptying fuel tank”, page 41
⇒ “2.4 Removing and installing misfuelling prevention device”,
page 51
⇒ “2.5 Deactivating misfuelling prevention device”, page 55

2.1 Assembly overview - fuel tank

⇒ “2.1.1 Assembly overview - fuel tank, Passat and Arteon with
front-wheel drive”, page 16
⇒ “2.1.2 Assembly overview - fuel tank, Tiguan with front-wheel
drive”, page 18
⇒ “2.1.3 Assembly overview - fuel tank, vehicles with four-wheel
drive”, page 20

2.1.1 Assembly overview - fuel tank, Passat and Arteon with front-wheel drive

1 - Cap
❑ Screw in until engages
audibly
❑ Secured to tank flap unit
2 - Filler pipe
3 - Bolt
❑ Qty. 2
❑ Renew after removal
❑ 8 Nm +90°
4 - Bump stop
❑ Between fuel tank and
vehicle body
❑ Ensure proper seating.
5 - Support
6 - Bolt
❑ Renew after removal
❑ 20 Nm +90°
7 - Fuel
❑ Removing and installing
⇒ page 21
8 - Heat shield
❑ For fuel tank
9 - Panel nut
❑ Qty. 4
❑ For heat shield
10 - Securing strap
❑ Check that the installa‐
tion position is correct.
❑ Mark direction of travel
when removing.

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❑ Fitting position ⇒ page 17
11 - Securing strap
❑ Check that the installation position is correct.
❑ Mark direction of travel when removing.
❑ Fitting position ⇒ page 17
12 - Fuel line
13 - Fuel pump control unit - J538-
❑ Removing and installing ⇒ page 111
14 - Fuel delivery unit, fuel gauge sender
❑ Assembly overview ⇒ page 56
❑ Removing and installing ⇒ page 64
15 - Earth connection
❑ For fuel filler neck
❑ To eliminate electrostatic charge

Components of fuel tank holder

1- Securing strap/fuel tank
2- Bolt with washer
3- Rubber bracket
4- Guide bush

Installation position of bleeder grommet

Before removing breather grommet, mark installation position.
When installing the fuel tank -2-, take the installation position of
the vent nipple -1- into account.
• Angle -α- must be approx. 60°.

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2.1.2 Assembly overview - fuel tank, Tiguan with front-wheel drive

1 - Cap
❑ Screw in until engages
audibly
❑ Secured to tank flap unit
2 - Filler neck
3 - Earth connection
❑ For fuel filler neck
❑ To eliminate electrostat‐
ic charge
4 - Bolt
❑ Renew after removal
❑ 8 Nm +90°
5 - Vent nipple
❑ Fitting position
⇒ page 19
6 - Bump stop
❑ Qty. 2
❑ Between fuel tank and
vehicle body
❑ Ensure proper seating.
7 - Fuel
❑ Removing and installing
⇒ page 27
8 - Fuel delivery unit, fuel
gauge sender
❑ Assembly overview
⇒ page 56
❑ Removing and installing
⇒ page 64
9 - Bolt
❑ Renew after removal
❑ 20 Nm +90°
10 - Clamping washer
❑ For heat shield
❑ Captive element to prevent loss
11 - Heat shield
❑ For fuel tank
12 - Bolt
❑ Renew after removal
❑ 20 Nm +90°
❑ For securing strap
13 - Securing strap
❑ Observe installation position
14 - Bracket
❑ For fuel pump control unit - J538- .
❑ Removing and installing fuel pump control unit - J538- ⇒ page 111 .

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15 - Fuel return line

❑ From engine
❑ Clipped onto fuel tank
❑ Do not kink
16 - Fuel supply line
❑ To engine
❑ Clipped onto fuel tank
❑ Do not kink

Installation position of bleeder grommet

Before removing breather grommet, mark installation position.
When installing the fuel tank -2-, take the installation position of
the vent nipple -1- into account.
• Angle -α- must be approx. 60°.

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

1 - Earth connection
❑ For fuel filler neck
❑ To eliminate electrostat‐
ic charge
2 - Cap
❑ Screw in until engages
audibly
❑ Secured to tank flap unit
3 - Bolt
❑ Renew after removal
❑ Qty. 2
❑ 8 Nm +90°
4 - Bump stop
❑ Between fuel tank and
vehicle body
❑ Ensure proper seating.
5 - Bolt
❑ Renew after removal
❑ 20 Nm +90°
❑ Passat and Arteon qty. 6
❑ Tiguan qty. 5
6 - Guide
7 - Fuel delivery unit, fuel
gauge sender
❑ Assembly overview
⇒ page 60
❑ Note installation posi‐
tion on fuel tank
8 - Fuel
❑ Removing and installing
⇒ page 34
9 - Fuel gauge sender 2 - G169-
❑ Assembly overview ⇒ page 60
10 - Securing strap
❑ Note installation position ⇒ page 21
11 - Heat shield
❑ Ensure secure seating
12 - Panel nut
❑ For heat shield
13 - Fuel lines
❑ Do not kink
❑ Disconnecting and connecting ⇒ page 80
❑ Note direction of arrow (fuel supply or fuel return system) on flange when installing
❑ Clipped onto fuel tank
14 - Bracket
❑ For fuel pump control unit - J538-

20 Rep. gr.20 - Fuel supply system

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❑ Removing and installing fuel pump control unit - J538- ⇒ page 111 .

Components of fuel tank holder, Passat and Arteon

1- Securing strap/fuel tank
2- Bolt with washer
3- Rubber bracket
4- Guide bush

Installation position of bleeder grommet

Before removing breather grommet, mark installation position.
When installing the fuel tank -2-, take the installation position of
the vent nipple -1- into account.
• Angle -α- must be approx. 60°.

2.2 Removing and installing fuel tank

⇒ “2.2.1 Removing and installing fuel tank - Passat and Arteon
with front-wheel drive”, page 21
⇒ “2.2.2 Removing and installing fuel tank - Tiguan with front-
wheel drive”, page 27
⇒ “2.2.3 Removing and installing fuel tank - vehicles with four-
wheel drive”, page 34

2.2.1 Removing and installing fuel tank - Pas‐

sat and Arteon with front-wheel drive
Special tools and workshop equipment required

2. Fuel 21
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♦ Torque wrench - V.A.G 1331-

♦ Removal wedge - 3409-

♦ Engine and gearbox jack - VAS 6931-

♦ Torque wrench - V.A.G 1332-

Removing
– Drain fuel tank ⇒ page 41 .
– Move front seats to foremost position.
– Switch off ignition.
– Remove cover of assembly opening on right ⇒ page 77 .

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– Release and pull off electrical connectors -1- and -2- on flange.
– If installed, release and pull off connector -3- for metering
pump - V54- .
– Remove fuel pump control unit - J538- with wiring harness still
attached ⇒ page 111 .
– Guide fuel pump control unit - J538- out towards interior be‐
tween fuel tank and floor panel.
– Place fuel pump control unit - J538- together with wiring har‐
ness to one side.

– Open tank flap unit -2-.

– Clean area around fuel filler neck.
– Unscrew cap -1- for fuel filler neck.
– In order to prevent the ingress of dirt, seal the opening of the
fuel filler neck with a clean plug.
– Remove rear right wheel ⇒ Running gear, axles, steering;
Rep. gr. 44 ; Wheels, tyres; Wheel change .
– Remove rear right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liner; Assembly
overview - rear wheel housing liner .
– If underbody cladding is fitted in front of right rear axle, remove
it ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody
cladding; Assembly overview - underbody cladding .
– Remove tank flap unit -2- ⇒ General body repairs, exterior;
Rep. gr. 55 ; Tank flap unit; Removing and installing tank flap
unit .
Vehicles with SCR system:
– Remove filler pipe for reducing agent tank ⇒ Rep. gr. 26 ;
SCR system (selective catalytic reduction) .

Continued for all vehicles:

– Unscrew bolts -1- and -2- for fuel filler neck.
– Remove rear part of exhaust system ⇒ Rep. gr. 26 ; Exhaust
system/silencer; Assembly overview - silencers .

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– Disconnect fuel line -1- on underbody. Separate plug-in con‐

nectors ⇒ page 80 .

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

– Disconnect fuel return line -2-. Separate plug-in connectors

⇒ page 80 .

Vehicles with auxiliary heater:

– Disconnect fuel line -1- to auxiliary heating. Separate plug-in
connectors ⇒ page 80 .

Continued for all vehicles:

– Mark installation position between wheel bearing housing -1-
and trailing arm -2-.
– To do this, use a suitable marker pen.
– Make a mark on the trailing arm in the area shown -arrow-.

– Unclip wiring harness -1- from trailing arm -2- -arrows-.

– Unscrew bolts -3-, and swing trailing arm -2- downwards.

24 Rep. gr.20 - Fuel supply system

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– Place engine and gearbox jack - VAS 6931- -2- underneath,

and support fuel tank -1- as shown in illustration.

2. Fuel 25
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– Unscrew bolts -arrows-.

Note

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

– Lower fuel tank -1- using engine and gearbox jack - VAS
6931- .
– Lower fuel tank by turning it sideways.
– Guide filler neck out between rear axle and body.
Installing
Install in reverse order of removal. The following should be ob‐
served:

Note

Separate plug-in connectors ⇒ page 80 .

– Install breather lines and fuel lines free of kinks.

– Guide filler neck in between rear axle and body.
– If fitted, check that metering pump - V54- is firmly seated.
– Ensure that the filler neck of the fuel tank is correctly inserted
into the opening in the body.
– Ensure rubber buffers are seated correctly
⇒ Item 4 (page 16) .
– Observe installation position of breather grommet
⇒ page 17 .
– Fit securing straps on holders on fuel tank.
– Position the fuel tank together with securing strap on under‐
body, using the engine and gearbox jack - VAS 6931- .
– Ensure that bracket for exhaust system is seated correctly ⇒
Rep. gr. 26 ; Exhaust pipes/silencers; Assembly overview -
silencers .
– Note position of securing strap.
– Ensure that line connections are tight.
– After installing fuel tank, check that the supply, return and
breather lines are still clipped onto the fuel tank.

26 Rep. gr.20 - Fuel supply system

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– Align wheel bearing housing -1- and trailing arm -2- in relation
to each other.
– To do this, use the mark previously made -arrow-.
– Tighten bolt -3-.

– 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 the connection of the metal ring on the fuel filler neck
by measuring between the ring and a bare metal part of the
body using an ohmmeter.
• Specification: approx. 0 ohm.
• If the specification is not attained, there is a risk of explosion
due to electrostatic discharge.
Specified torques
♦ ⇒ “2.1.1 Assembly overview - fuel tank, Passat and Arteon with
front-wheel drive”, page 16
♦ ⇒ Rep. gr. 26 ; SCR system (selective catalytic reduction);
Assembly overview - reducing agent tank
♦ ⇒ General body repairs, interior; Rep. gr. 72 ; Rear seat;
Removing and installing bench seat / individual seats
♦ ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Assembly overview
- silencers
♦ ⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit;
Removing and installing tank flap unit
♦ ⇒ Running gear, axles, steering; Rep. gr. 42 ; Rear axle;
Overview - rear axle
♦ ⇒ Running gear, axles, steering; Rep. gr. 42 ; Wheel bearing,
trailing arm; Assembly overview - wheel bearing
♦ ⇒ Running gear, axles, steering; Rep. gr. 42 ; Wheel bearing;
Assembly overview - trailing arm

2.2.2 Removing and installing fuel tank - Ti‐

guan with front-wheel drive
Special tools and workshop equipment required

2. Fuel 27
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♦ Torque wrench - V.A.G 1331-

♦ Removal wedge - 3409-

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

♦ Engine and gearbox jack - VAS 6931-

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♦ Torque wrench - V.A.G 1332-

Removing
– Move front seats to foremost position.
– Switch off ignition.
– Remove cover of assembly opening ⇒ page 77 .
– Release and pull off connectors -2- and -3- on sealing flange.
– If fitted, detach, release and pull off electrical connector -6-.
– Remove fuel pump control unit - J538- with wiring harness still
attached ⇒ page 111 .
– Guide fuel pump control unit - J538- out towards interior be‐
tween fuel tank and floor panel.
– Place fuel pump control unit - J538- together with wiring har‐
ness to one side.
– Remove rear right wheel ⇒ Running gear, axles, steering;
Rep. gr. 44 ; Wheels, tyres and alignment .
– Remove rear right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liner; Assembly
overview - rear wheel housing liner .

– Open tank flap unit -2-.

– Clean area around fuel filler neck.
– Unscrew cap -1- for fuel filler neck.
– In order to prevent the ingress of dirt, seal the opening of the
fuel filler neck with a clean plug.
– Remove tank flap unit -2- ⇒ General body repairs, exterior;
Rep. gr. 55 ; Tank flap unit; Removing and installing tank flap
unit .

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– Guide sealing grommet -1- out of filler pipes -arrows-.

– Pull sealing grommet -1- off body -2-, and remove it.

– Unscrew bolts -1- and -2- for fuel filler neck.

Vehicles with SCR system:
– Remove filler pipe for tank for reducing agent ⇒ Rep. gr. 26 ;
SCR system (selective catalytic reduction), Assembly over‐
view - tank for reducing agent .
Continued for all vehicles:
– Remove rear left and right underbody cladding ⇒ General
body repairs, exterior; Rep. gr. 66 ; Underbody cladding; Re‐
moving and installing underbody cladding .
– Detach underbody cladding on left and right in centre and low‐
er ⇒ General body repair, exterior; Rep. gr. 66 ; Underbody
cladding .
– Remove trim on rear axle ⇒ Running gear, axles, steering;
Rep. gr. 42 ; Rear axle; Removing and installing rear axle .
– Remove rear section of exhaust system ⇒ Rep. gr. 26 ; Ex‐
haust pipes/silencers; Removing and installing silencer .
– Remove rear tunnel cross-piece ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Underbody cladding; Removing and
installing tunnel cross-piece .

– Disconnect fuel supply lines -1- and -2- at underbody. Sepa‐

rate plug-in connectors ⇒ page 80 .
Vehicles with auxiliary heater
– Disconnect fuel line -3- to auxiliary heating. Separate plug-in
connectors ⇒ page 80 .

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Continued for all vehicles

– Mark installation position between wheel bearing housing -1-
and rear right trailing arm -2-.
– To do this, use a suitable marker pen.
– Make a mark on the trailing arm in the area shown -arrow-.

– Unclip wiring harness -1- from trailing arm -2- -arrows-. Press
out inner retaining pins to do this.
– Support wheel bearing unit on engine and gearbox jack ⇒
Running gear, axles, steering; Rep. gr. 42 ; Wheel bearing,
trailing arm; Assembly overview - wheel bearing .
– Unscrew bolts -3-, and swing trailing arm -2- downwards.

– Unscrew bolts -arrows A-.

– Remove securing strap -2-.

– Remove heat shield on fuel tank -1-.

– To do this, remove clamping washers -arrows-.
– Unhook heat shield from studs.
– Guide out heat shield and remove.

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– Place engine and gearbox jack -2- under fuel tank -1- to sup‐
port it.

– Unscrew bolts -arrows B-.

Note

For illustration purposes, the fuel tank is shown without engine

and gearbox jack .

– Support fuel tank with engine and gearbox jack to prevent it

from falling down.
– Lower fuel tank using engine and gearbox jack .
– Lower fuel tank by turning it sideways.
– Guide out lines to activated charcoal filter on rear axle.
– Guide filler neck out between rear axle and body.
Installing
Install in reverse order of removal. The following should be ob‐
served:
– Guide filler neck in between rear axle and body.
– If metering pump - V54- is fitted, ensure that it is securely fas‐
tened to bracket.
– Ensure that the filler neck of the fuel tank is correctly inserted
into the opening in the body.
– Install breather lines and fuel lines free of kinks.
– After installing fuel tank, check that the supply, return and
breather lines are still clipped onto the fuel tank.
– Ensure rubber buffers are seated correctly
⇒ Item 6 (page 18) .
– Observe installation position of breather grommet
⇒ page 19 .
– Clip in lines for auxiliary heater on fuel tank.

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– Use engine and gearbox jack - V.A.G 1383 A- to position fuel

tank on underbody.

Note

For illustration purposes, the fuel tank is shown without engine

and gearbox jack .

– Tighten bolts -arrows B- by hand.

– Lower engine and gearbox jack - V.A.G 1383 A- .
– Guide in breather lines on rear axle.
– When clipping in the lines, take note of the different diameters.
– Install heat shield.
– Attach securing strap and tighten bolts -arrows A- by hand.
– Note installation position of securing strap.
– Ensure that bracket for exhaust system is seated correctly ⇒
Rep. gr. 26 ; Exhaust pipes/silencers; Assembly overview -
silencers .
– Ensure that line connections are tight.
– Ensure connections are secured properly by pulling.

– Align wheel bearing housing -1- and trailing arm -2- in relation
to each other.
– To do this, use the mark previously made -arrow-.
– Tighten bolt -3-.

– 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 tab -1- must be hooked into fuel tank -4- and secured
by means of spacer bush -5-.
– Check the connection of the metal ring on the fuel filler neck
by measuring between the ring and a bare metal part of the
body using an ohmmeter.
• Specification: approx. 0 ohm.
• If the specification is not attained, there is a risk of explosion
due to electrostatic discharge.

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– Make sure that sealing grommet -1- is properly seated.

– To install trailing arm, lift wheel bearing unit on engine and
gearbox jack until upper bolt can be inserted.
– Fill fuel tank with at least 5 litres of fuel.
Specified torques
♦ ⇒ “2.1 Assembly overview - fuel tank”, page 16
♦ ⇒ Rep. gr. 26 ; SCR system (selective catalytic reduction);
Assembly overview - reducing agent tank
♦ ⇒ Running gear, axles, steering; Rep. gr. 42 ; Wheel bearing,
trailing arm; Assembly overview - wheel bearing
♦ ⇒ Running gear, axles, steering; Rep. gr. 42 ; Wheel bearing;
Assembly overview - trailing arm
♦ ⇒ General body repairs, interior; Rep. gr. 72 ; Rear seat;
Removing and installing bench seat / individual seats
♦ ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Assembly overview
- silencers
♦ ⇒ Running gear, axles, steering; Rep. gr. 42 ; Subframe; As‐
sembly overview - subframe
♦ ⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit;
Removing and installing tank flap unit
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody
cladding
♦ ⇒ Running gear, axles, steering; Rep. gr. 42 ; Rear axle

2.2.3 Removing and installing fuel tank - ve‐

hicles with four-wheel drive
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

♦ Removal wedge - 3409-

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♦ Engine and gearbox jack - VAS 6931-

♦ Torque wrench - V.A.G 1332-

Removing
– Drain fuel tank ⇒ page 41 .
– Move front seats to foremost position.
– Switch off ignition.
– Remove cover of assembly opening on left and right
⇒ page 77 .
– Release and pull off connector -2- on sealing flange.
Vehicles with auxiliary heater
– Release and pull off connector -3- for metering pump - V54- .

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Continued for all vehicles

– Release and pull off connector -2- on sealing flange.
– Release and pull off connector -1- on sealing flange.
– If fitted, release and pull off electrical connector -3- on flange.
– Unclip electrical connectors from mountings on flange.
– Remove fuel pump control unit - J538- with wiring harness still
attached ⇒ page 111 .
– Guide fuel pump control unit - J538- out towards interior be‐
tween fuel tank and floor panel.
– Place fuel pump control unit - J538- together with wiring har‐
ness to one side.

– Open tank flap unit.

– Clean area around fuel filler neck.
– Unscrew cap -2- for fuel filler neck.
– If fitted, unscrew filler cap -1- for filler neck of reducing agent
tank.
– In order to prevent the ingress of dirt, seal the opening of the
fuel filler neck with a clean plug.
– Remove rear right wheel ⇒ Running gear, axles, steering;
Rep. gr. 44 ; Wheels, tyres; Wheel change .
– Remove rear right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liner; Assembly
overview - rear wheel housing liner .
– Remove tank flap unit -2- ⇒ General body repairs, exterior;
Rep. gr. 55 ; Tank flap unit; Removing and installing tank flap
unit .

Tiguan:
– Guide sealing grommet -1- out of filler pipes -arrows-.
– Pull sealing grommet -1- off body -2-, and remove it.
Vehicles with SCR system:
– Remove filler pipe for reducing agent tank ⇒ Rep. gr. 26 ;
SCR system (selective catalytic reduction) .

Continued for all vehicles:

– Unscrew bolts -1- and -2- for fuel filler neck.
– If fitted, remove left and right rear underbody cladding in front
of rear axle ⇒ General body repairs, exterior; Rep. gr. 66 ;
Underbody cladding; Removing and installing underbody clad‐
ding .
– Remove rear part of exhaust system ⇒ Rep. gr. 26 ; Exhaust
system/silencer; Assembly overview - silencers .

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– Disconnect fuel line -1- on underbody. Separate plug-in con‐

nectors ⇒ page 80 .

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

– Disconnect fuel return line -2-. Separate plug-in connectors

⇒ page 80 .

Vehicles with auxiliary heater:

– Disconnect fuel line -1- to auxiliary heating. Separate plug-in
connectors ⇒ page 80 .

Continued for all vehicles:

– Remove propshaft ⇒ Propshaft and rear final drive; Rep. gr.
39 ; Propshaft; Removing and installing propshaft .
– Release and pull off connector -1- for Haldex coupling.
– Unclip wiring harness from fuel tank and heat shield.

– Mark installation position between wheel bearing housing -1-

and trailing arm -2-.
– To do this, use a suitable marker pen.
– Make a mark on the trailing arm in the area shown -arrow-.

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– Unclip wiring harness -1- from trailing arm -2- -arrows-.

– Unscrew bolts -3-, and swing trailing arm -2- downwards.

– If present, remove spoiler -1- and -13-. To do this, unscrew

nuts -2- and -14-.
– If present, remove underbody cladding -6- and -11- ⇒ General
body repairs, exterior; Rep. gr. 66 ; Underbody cladding; Re‐
moving and installing underbody cladding .

– Place engine and gearbox jack -2- underneath, and support

fuel tank -1- as shown in illustration.

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– Unscrew bolts -arrows-.

Note

♦ The number of bolts differs depending on the vehicle model.

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

– Have a 2nd mechanic support fuel tank at back edge by hand.

– Lower fuel tank using engine and gearbox jack.
– Lower fuel tank by turning it sideways.
– Guide filler neck out between rear axle and body.
– A 2nd mechanic will be required to guide out fuel filler neck
past trailing arm by hand.
Installing
Install in reverse order of removal. The following should be ob‐
served:
– Install breather lines and fuel lines free of kinks.
– Ensure rubber buffers are seated correctly
⇒ Item 4 (page 16) .
– Guide filler neck in between rear axle and body.
– If fitted, check that metering pump - V54- is firmly seated.
– Ensure that the filler neck of the fuel tank is correctly inserted
into the opening in the body.
– Position the fuel tank together with securing strap on under‐
body, using the engine and gearbox jack - V.A.G 1383 A- .
– Ensure that bracket for exhaust system is seated correctly ⇒
Rep. gr. 26 ; Exhaust pipes/silencers; Assembly overview -
silencers .
– Note position of securing strap.
– Ensure that line connections are tight.
– After installing fuel tank, check that the supply, return and
breather lines are still clipped onto the fuel tank.
– Observe installation position of breather grommet
⇒ Fig. ““Installation position of bleeder grommet”“ , page 21 .
– To install trailing arm, lift wheel bearing unit on engine and
gearbox jack until upper bolt can be inserted.

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– Align wheel bearing housing -1- and trailing arm -2- in relation
to each other.
– To do this, use the mark previously made -arrow-.
– Tighten bolt -3-.

– 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 the connection of the metal ring on the fuel filler neck
by measuring between the ring and a bare metal part of the
body using an ohmmeter.
• Specification: approx. 0 ohm.
• If the specification is not attained, there is a risk of explosion
due to electrostatic discharge.

Tiguan:
– Make sure that sealing grommet -1- is properly seated.
Continued for all vehicles:
– Fill fuel tank with at least 5 litres of fuel.
Specified torques

Component Specified torque

Nuts for spoilers 2 Nm

♦ ⇒ “2.1.3 Assembly overview - fuel tank, vehicles with four-

wheel drive”, page 20
♦ ⇒ Propshaft and rear final drive; Rep. gr. 39 ; Propshaft; As‐
sembly overview - propshaft
♦ ⇒ General body repairs, interior; Rep. gr. 72 ; Rear seat;
Removing and installing bench seat / individual seats
♦ ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Assembly overview
- silencers
♦ ⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit;
Removing and installing tank flap unit
♦ ⇒ Rep. gr. 26 ; SCR system (selective catalytic reduction);
Assembly overview - reducing agent tank

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♦ ⇒ Running gear, axles, steering; Rep. gr. 42 ; Wheel bearing,

trailing arm; Assembly overview - wheel bearing
♦ ⇒ Running gear, axles, steering; Rep. gr. 42 ; Wheel bearing;
Assembly overview - trailing arm
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody
cladding; Overview of fitting locations - underbody cladding

2.3 Emptying fuel tank

⇒ “2.3.1 Emptying fuel tank when fuel pump is intact”,
page 41
⇒ “2.3.2 Emptying fuel tank if more than 3/4 full, Passat and Ar‐
teon”, page 42
⇒ “2.3.3 Emptying fuel tank if more than 3/4 full, Tiguan”,
page 44
⇒ “2.3.4 Emptying fuel tank less than 3/4 full, vehicles with front-
wheel drive”, page 45
⇒ “2.3.5 Emptying fuel tank less than 3/4 full, vehicles with four-
wheel drive”, page 48

2.3.1 Emptying fuel tank when fuel pump is

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

♦ Adapter for fuel extraction - VAS 5190-

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Note

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

– Unscrew tip -1- from extraction hose of fuel extraction unit -

VAS 5190- .
– Screw fuel extraction adapter - VAS 5190 /2- from fuel extrac‐
tion adapter set - VAS 5190 /10- onto extraction hose.
Removing
– Switch off ignition.

– Pull off supply line -B-, and catch escaping fuel with a cloth.
Separate plug-in connectors ⇒ page 80 .

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

– Connect fuel extractor - VAS 5190- with adapter for fuel ex‐
tractor - VAS 5190 /3 - to fuel supply line.
– Connect ⇒ Vehicle diagnostic tester.

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.

– Carry out guided function empty fuel tank ; this will actuate
fuel pump.
– Repeat the function if necessary.
– Open shut-off tap on fuel extractor - VAS 5190- until fuel tank
is emptied.

Note

The cut-off valve of vehicles with all-wheel drive must be closed

periodically. This creates counter pressure in the fuel supply line,
and the suction-jet pump in the fuel tank is actuated.

2.3.2 Emptying fuel tank if more than 3/4 full,

Passat and Arteon
Special tools and workshop equipment required

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♦ Fuel extractor - VAS 5190-

♦ Fuel extractor - VAS 5190 A- (not shown)

♦ Funnel - T40256- for vehicles with misfuelling prevention de‐
vice

– Make a mark on the hose -arrow- at distance -a- from end of

extraction hose.
– Use insulating tape for this.
– Dimension -a- is 880 mm.

– Open tank flap unit -2-.

– Clean area around fuel filler neck.
– Unscrew cap -1- for fuel filler neck.

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Vehicles with misfuelling prevention device

– Insert funnel - T40256- into fuel filler neck as far as it will go.
– Push extraction hose of fuel extraction unit into fuel tank until
the mark that was previously applied -2- coincides with the
edge of the funnel - T40256- .
– If the funnel - T40256- is not available, the misfuelling preven‐
tion device must be removed ⇒ page 51 .

Note

On vehicles with four-wheel drive, only the right chamber of the

fuel tank needs to be emptied.

Continued for all vehicles

– Drain fuel tank via filler neck as far as possible.

Note

There is a valve -2- in the fuel tank -1- at the lower end of the filler
neck. The valve must not be damaged by the extraction hose
-3-. Therefore push hose into filler neck only as far as marking
-arrow-.

– Pull extraction hose out carefully.

Note

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

enough for the sender flange to be opened without danger.
♦ If work has to be done on fuel delivery unit or on fuel gauge
sender , proceed as follows ⇒ page 45 :

2.3.3 Emptying fuel tank if more than 3/4 full,

Tiguan
Special tools and workshop equipment required
♦ Fuel extractor - VAS 5190 A-

44 Rep. gr.20 - Fuel supply system

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– Make a mark -arrow- at dimension -a- from end of extraction

hose of fuel extractor - VAS 5190- .
– Use insulating tape for this.
– Dimension -a- is 1100 mm.

– Open tank flap unit -2-.

– Clean area around fuel filler neck.
– Unscrew cap -1- for fuel filler neck.
– Secure earth wire of fuel extractor to a bare metal part of the
body.

– Push extraction hose of extraction unit into fuel tank until pre‐
viously attached marking -arrow- on hose coincides with filler
neck -2-.
– Drain fuel tank via filler neck as far as possible.

Note

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

– Pull extraction hose out carefully.

Note

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

enough for the sender flange to be opened without danger.
♦ If work has to be done on fuel delivery unit or on fuel gauge
sender , proceed as follows ⇒ page 56 :

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

2. Fuel 45
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Special tools and workshop

equipment required

♦ Fuel extractor - VAS 5190-

♦ Fuel tank sender unit tool - T10202-
♦ Torque wrench (40 … 200 Nm) - V.A.G 1332-
♦ Removal wedge - 3409-
♦ Fuel extractor - VAS 5190 A- (not shown)
Passat and Arteon:
– Remove cover of assembly opening on right ⇒ page 77 .
Tiguan:
– Remove cover of assembly opening ⇒ page 77 .

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Continued for all vehicles:

– Release and pull off electrical connectors -1- and -2- on flange.
Vehicles with auxiliary heater:
– Detach connector -3- for metering pump - V54- from sealing
flange.
– Release and pull off connector -3- for metering pump - V54- .
Continued for all vehicles:
– Remove fuel pump control unit - J538- ⇒ page 111 .
– Remove fuel pump control unit - J538- together with wiring
harness and lay aside.

– Disconnect fuel return line -1- at sealing flange. Separate plug-

in connectors ⇒ page 80 .

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

– Disconnect fuel return line -2- at flange. Separate plug-in con‐

nectors ⇒ page 80 .
Vehicles with auxiliary heater:
– Detach fuel line -3- leading to metering pump - V54- for aux‐
iliary heater from sealing flange ⇒ page 120 .

Continued for all vehicles:

– Open locking ring using fuel tank sender unit tool - T10202- .

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– Carefully lift flange of fuel delivery unit -3-.

– Remove gasket -1- and carefully lift up the flange of the fuel
delivery unit slightly more.
– Secure earth wire of fuel extractor to a bare metal part of the
body.
– Insert suction hose of fuel extractor as far as possible into fuel
tank.
– Extract fuel using fuel extractor.
If fuel tank needs only to be emptied, install fuel delivery unit
again. ⇒ page 64 .
Specified torques
♦ ⇒ “3.1 Assembly overview - fuel delivery unit/fuel gauge send‐
er”, page 56
♦ ⇒ Auxiliary heater; Rep. gr. 82 ; Fuel supply system; Overview
of fitting locations – fuel supply system .

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

Special tools and workshop

equipment required

48 Rep. gr.20 - Fuel supply system

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♦ Fuel extractor - VAS 5190-

♦ Fuel tank sender unit tool - T10202-
♦ Torque wrench (40 … 200 Nm) - V.A.G 1332-
♦ Removal wedge - 3409-
♦ Fuel extractor - VAS 5190 A- (not shown)
– Drain fuel tank ⇒ page 41 .
– Remove cover of assembly opening on left and right
⇒ page 77 .
– Release and pull off electrical connectors -1- and -2- on flange.
Vehicles with auxiliary heater:
– Detach connector -3- for metering pump - V54- from sealing
flange.
– Release and pull off connector -3- for metering pump - V54- .
Continued for all vehicles:
– Remove fuel pump control unit - J538- ⇒ page 111 .
– Remove fuel pump control unit - J538- together with wiring
harness and lay aside.

– Disconnect fuel return line -1- at sealing flange. Separate plug-

in connectors ⇒ page 80 .

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

– Disconnect fuel return line -2- at flange. Separate plug-in con‐

nectors ⇒ page 80 .
Vehicles with auxiliary heater:
– Detach fuel line -3- leading to metering pump - V54- for aux‐
iliary heater from sealing flange ⇒ page 120 .

Continued for all vehicles:

– Open locking ring using fuel tank sender unit tool - T10202- .

2. Fuel 49
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– Carefully lift flange of fuel delivery unit -3-.

– Remove gasket -1- and carefully lift up the flange of the fuel
delivery unit slightly more.
– Secure earth wire of fuel extractor to a bare metal part of the
body.
– Insert suction hose of fuel extractor as far as possible into fuel
tank.
– Extract fuel using fuel extractor.

– Release and pull off connector -2- on sealing flange.

– Release and pull off connector -1- on sealing flange.
– If fitted, release and pull off electrical connector -3- on flange.
– Unclip electrical connectors from mountings on flange.

– Open locking ring using fuel tank sender unit tool - T10202- .

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– Carefully pull sealing flange -3- on left together with suction-

jet pump -1- a short distance out of opening in fuel tank.
– Insert suction hose of fuel extractor as far as possible into fuel
tank.
– Extract fuel using fuel extractor.
If fuel tank needs only to be emptied:
– Install fuel delivery unit ⇒ page 64 .
– Install fuel gauge sender 2 - G169- ⇒ page 64 .
Specified torques
♦ ⇒ “3.1 Assembly overview - fuel delivery unit/fuel gauge send‐
er”, page 56
♦ ⇒ “3.4 Removing and installing fuel gauge sender 2 G169 ”,
page 73
♦ ⇒ Auxiliary heater; Rep. gr. 82 ; Fuel supply system; Overview
of fitting locations – fuel supply system .

2.4 Removing and installing misfuelling pre‐

vention device
⇒ “2.4.1 Removing and installing misfuelling prevention device,
plastic cap”, page 51
⇒ “2.4.2 Removing and installing misfuelling prevention device,
metal cap”, page 54

2.4.1 Removing and installing misfuelling pre‐

vention device, plastic cap
Special tools and workshop equipment required
♦ Snap ring pliers
Removing
– Open tank flap unit -2-.
– Clean area around fuel filler neck.
– Unscrew cap -1- for fuel filler neck.

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– Release locking ring locking lug with, for example, a T15 Torx
screwdriver -arrow-.

– Insert circlip pliers into both holes -arrows- of locking ring.

– Turn locking ring about 25° in anti-clockwise direction.

– Tilt locking ring in fuel filler neck and remove ring through cut-
out -arrows- for sealing cap.

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– Pull misfuelling prevention device out of fuel filler neck

-arrow-, using circlip pliers, if necessary.
Installing
Install in reverse order of removal. The following should be ob‐
served:

– Insert misfuelling prevention device in fuel filler neck.

– Insert smaller lug in misfuelling prevention device into groove
in fuel filler neck -arrows-.

– Install locking ring using circlip pliers, in process turn locking

ring 25° clockwise.

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– When installed correctly the marks on the locking ring and on

the fuel filler neck must align -arrows-.

2.4.2 Removing and installing misfuelling pre‐

vention device, metal cap
Special tools and workshop equipment required
♦ Release strips from the repair set
Removing
– Open tank flap unit -2-.
– Clean area around fuel filler neck.
– Unscrew cap -1- for fuel filler neck.

– Insert release strips -1- in both guides in the fuel filler neck until
contact is made -arrows-, as shown in the illustration.
• The offset of the release strips face one another.
• The release strips can be heard to engage.
• Guiding in the release strips will unlock the misfuelling pre‐
vention device -1- and it can be removed.

– Pull the misfuelling prevention device out of the fuel filler neck
-arrow-.

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Installing
– Insert misfuelling prevention device in fuel filler neck.
• The retaining hook -arrow 2- must grip in the guide -arrow 1-
on the misfuelling prevention device.
• It is not possible to insert from the wrong side.
– Push the misfuelling prevention device into the filler neck until
it can be heard to engage.

2.5 Deactivating misfuelling prevention de‐

vice
⇒ “2.5.1 Deactivating the misfuelling prevention device, plastic
cap”, page 55
⇒ “2.5.2 Deactivating the misfuelling prevention device, metal
cap”, page 55

2.5.1 Deactivating the misfuelling prevention

device, plastic cap
Sequence of operations
– Remove misfuelling prevention device ⇒ page 51 .
– Remove locking lugs at markings as shown in illustration.

Note

The sealing cap of the misfuelling prevention device must open

without catching.

– Install misfuelling prevention device ⇒ page 51 .

2.5.2 Deactivating the misfuelling prevention

device, metal cap

Note

♦ If the misfuelling prevention device is to be deactivated, simply

removing the misfuelling prevention device is not enough.
♦ Danger due to electrostatic charge
♦ The misfuelling prevention device is connected to earth via the
fuel tank.
♦ A deactivated misfuelling prevention device must be fitted
which will reconnect the earth connection to the fuel tank ⇒
Electronic Parts Catalogue .

– Removing and installing misfuelling prevention device

⇒ page 54 .

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3 Fuel delivery unit, fuel gauge sender

⇒ “3.1 Assembly overview - fuel delivery unit/fuel gauge sender”,
page 56
⇒ “3.2 Removing and installing fuel delivery unit, fuel gauge send‐
er”, page 64
⇒ “3.3 Removing and installing fuel gauge sender G ”,
page 72
⇒ “3.4 Removing and installing fuel gauge sender 2 G169 ”, page
73
⇒ “3.5 Removing and installing assembly opening cover”,
page 77

3.1 Assembly overview - fuel delivery unit/

fuel gauge sender
⇒ “3.1.1 Assembly overview - fuel delivery unit/fuel gauge sender,
vehicles with front-wheel drive”, page 56
⇒ “3.1.2 Assembly overview - fuel delivery unit/fuel gauge sender,
vehicles with four-wheel drive”, page 60
⇒ “3.1.3 Assembly overview- fuel gauge sender, left, all-wheel
drive”, page 63

3.1.1 Assembly overview - fuel delivery unit/fuel gauge sender, vehicles with
front-wheel drive

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1 - Fuel delivery unit

❑ With fuel system pres‐
surisation pump - G6-
❑ Checking fuel system
pressurisation pump -
G6- ⇒ page 94 .
❑ Removing and installing
⇒ page 64
❑ After installing, fill vehi‐
cle with at least 5 litres
of fuel.
❑ Fitting position
⇒ page 58
2 - Seal
❑ Renew after removal
❑ Install dry
3 - Locking ring
❑ Remove and tighten
with wrench - T10202- .
❑ 110 Nm
4 - Fuel supply line
❑ To fuel filter
❑ Clipped onto fuel tank
❑ To pull off, press release
button on connection
❑ Plug-in connectors must
engage »audibly« when
joined
❑ Ensure plug-in connec‐
tor is secured properly
by pulling it.
❑ Disconnect plug-in con‐
nectors ⇒ page 80
❑ Connection diagram ⇒ page 58 Volkswagen Technical Site: http://vwts.ru http://vwts.info
❑ Observe notes reference fuel lines in the engine compartment ⇒ page 90 .
5 - Fuel pump control unit - J538-
❑ Checking ⇒ Vehicle diagnostic tester
❑ Removing and installing ⇒ page 111
6 - Electrical connector
❑ For fuel pump control unit - J538- .
❑ Make sure connectors are attached properly; pull to check that they are correctly engaged.
7 - Electrical connector
❑ For fuel system pressurisation pump - G6-
❑ Make sure connectors are attached properly; pull to check that they are correctly engaged.
8 - Electrical connector
❑ For fuel gauge sender - G-
❑ Make sure connectors are attached properly; pull to check that they are correctly engaged.
9 - Fuel return line
❑ From engine
❑ Clipped onto fuel tank
❑ To pull off, press release button on connection
❑ Plug-in connectors must engage »audibly« when joined

3. Fuel delivery unit, fuel gauge sender 57

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❑ Ensure plug-in connector is secured properly by pulling it.
❑ Disconnect plug-in connectors ⇒ page 80
❑ Connection diagram ⇒ page 58
❑ Observe notes reference fuel lines in the engine compartment ⇒ page 90 .
10 - Fuel gauge sender - G-
❑ Checking ⇒ Vehicle diagnostic tester
❑ Removing and installing ⇒ page 72

Installation position of fuel delivery unit

Passat and Arteon:
• The arrow -3- on the fuel tank must line up with the mark -2-
on the sealing flange -1-.

Tiguan:
– Push flange downwards against spring force and move flange
into installation position.
• Tab -2- on flange must be between lugs -1- and -3- on fuel
tank.
• -Arrow- points in direction of travel.

Fuel lines on fuel delivery unit

1- Fuel supply line
2- Fuel return line
3- Fuel line to metering pump - V54-

Fuel line for auxiliary heater

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1 - Sealing flange of fuel deliv‐

ery unit
2 - Clip
❑ Renew after removal
❑ Secure hose connection
with the hose clips cor‐
responding to original
equipment.
3 - Clip
❑ Renew after removal
❑ Secure hose connection
with the hose clips cor‐
responding to original
equipment.
4 - Fuel line
❑ To metering pump -
V54-
❑ Removing and installing
⇒ page 120
5 - Sealing grommet
❑ Check for damage
6 - Fuel line
❑ To engine

3. Fuel delivery unit, fuel gauge sender 59

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3.1.2 Assembly overview - fuel delivery unit/fuel gauge sender, vehicles with four-
wheel drive

1 - Suction-jet pump
❑ Checking ⇒ page 114
❑ Removing and installing
⇒ page 107
2 - Fuel delivery unit
❑ With fuel system pres‐
surisation pump - G6-
❑ Removing and installing
⇒ page 68
❑ Checking fuel system
pressurisation pump -
G6- ⇒ page 94 .
❑ Carrying out electrical
test of fuel pump in Gui-
ded fault finding
mode ⇒ Vehicle diag‐
nostic tester
❑ After installing, fill vehi‐
cle with at least 5 litres
of fuel.
❑ Fitting position
⇒ page 61
❑ Connection diagram
⇒ page 61
3 - Electrical connector
❑ For fuel gauge sender -
G-
❑ Ensure proper engage‐
ment; check firm seating
by pulling.
4 - Electrical connector
❑ For fuel pump control
unit - J538- .
❑ Ensure proper engage‐
ment; check firm seating by pulling.
5 - Electrical connector
❑ For fuel system pressurisation pump - G6-
❑ Ensure proper engagement; check firm seating by pulling.
6 - Fuel pump control unit - J538-
❑ Checking ⇒ Vehicle diagnostic tester
❑ Removing and installing ⇒ page 111
7 - Fuel return line
❑ From engine
❑ Do not kink
❑ Disconnecting and connecting ⇒ page 80
❑ Note direction of arrow (fuel supply or fuel return system) on flange when installing
❑ Clipped onto fuel tank
❑ Connection diagram ⇒ page 61
8 - Fuel supply line
❑ To fuel filter

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❑ Do not kink
❑ Disconnecting and connecting ⇒ page 80
❑ Note direction of arrow (fuel supply or fuel return system) on flange when installing
❑ Clipped onto fuel tank
❑ Connection diagram ⇒ page 61
9 - Locking ring
❑ Remove and tighten with wrench - T10202- .
❑ 110 Nm ±5 Nm
10 - Flange
❑ Fitting position ⇒ page 61
11 - Seal
❑ Renew after removal
❑ Install dry
12 - Fuel gauge sender - G-
❑ Checking ⇒ Vehicle diagnostic tester
❑ Removing and installing ⇒ page 72

Installation position of fuel delivery unit:

Passat and Arteon:
• The arrow -3- on the fuel tank must line up with the mark -2-
on the sealing flange -1-.

Tiguan:
– Push flange downwards against spring force and move flange
into installation position.
• Tab -2- on flange must be between lugs -1- and -3- on fuel
tank.
• -Arrow- points in direction of travel.

Fuel lines on fuel delivery unit

1- Fuel supply line
2- Fuel return line
3- Fuel line to metering pump - V54-

3. Fuel delivery unit, fuel gauge sender 61

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Fuel line for auxiliary heater

1 - Sealing flange of fuel deliv‐

ery unit
2 - Clip
❑ Renew after removal
❑ Secure hose connection
with the hose clips cor‐
responding to original
equipment.
3 - Clip
❑ Renew after removal
❑ Secure hose connection
with the hose clips cor‐
responding to original
equipment.
4 - Fuel line
❑ To metering pump -
V54-
❑ Removing and installing
⇒ page 120
5 - Sealing grommet
❑ Check for damage
6 - Fuel line
❑ To engine

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3.1.3 Assembly overview- fuel gauge sender, left, all-wheel drive

1 - Connector
2 - Fuel gauge sender 2 -
G169-
❑ Removing and installing
⇒ page 73
3 - Flange on left
❑ Removing and installing
⇒ page 73
4 - Seal
❑ Renew after removal
❑ Install dry
5 - Locking ring
❑ Remove and tighten
with wrench - T10202- .
❑ 110 Nm

Installation position of flange:

Passat and Arteon:
• The arrow -3- on the fuel tank must line up with the mark -2-
on the sealing flange -1-.

3. Fuel delivery unit, fuel gauge sender 63

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Tiguan:
– Push flange downwards against spring force and move flange
into installation position.
• Tab -2- on flange must be between lugs -1- and -3- on fuel
tank.
• -Arrow- points in direction of travel.

3.2 Removing and installing fuel delivery

unit, fuel gauge sender
⇒ “3.2.1 Removing and installing fuel delivery unit/fuel gauge
sender, vehicles with front-wheel drive”, page 64
⇒ “3.2.2 Removing and installing fuel delivery unit/fuel gauge
sender, vehicles with four-wheel drive”, page 68

3.2.1 Removing and installing fuel delivery

unit/fuel gauge sender, vehicles with
front-wheel drive
Special tools and workshop equipment required
♦ Special wrench - T10202-

♦ Torque wrench - V.A.G 1332-

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♦ Removal wedge - 3409-

Removing
– The fuel tank must not be more than 3/4 full. This ensures that
the fill level is below the flange of the fuel delivery unit.
– If necessary, drain fuel tank ⇒ page 41 .
– Move front seats to foremost position.
– Switch off ignition.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .
– Remove cover of assembly opening ⇒ page 77 .
– Release and pull off electrical connectors -1- and -2- on flange.
Vehicles with auxiliary heater:
– Detach connector -3- for metering pump - V54- from sealing
flange.
– Release and pull off connector -3- for metering pump - V54- .
Continued for all vehicles:
– Remove fuel pump control unit - J538- with wiring harness still
attached ⇒ page 111 .
– Guide fuel pump control unit - J538- out towards interior be‐
tween fuel tank and floor panel.
– Place fuel pump control unit - J538- together with wiring har‐
ness to one side.

– Disconnect fuel return line -1- at sealing flange. Separate plug-

in connectors ⇒ page 80 .

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

– Disconnect fuel return line -2- at flange. Separate plug-in con‐

nectors ⇒ page 80 .
Vehicles with auxiliary heater:
– Detach fuel line -3- leading to metering pump - V54- for aux‐
iliary heater from sealing flange ⇒ page 120 .

3. Fuel delivery unit, fuel gauge sender 65

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Continued for all vehicles:

– Open locking ring using wrench - T10202- .

– Carefully lift up flange -3-.

– Pull sealing flange -3- for a short distance out of the opening
in the fuel tank.
– Remove seal -1- at the opening in the fuel tank.
– Carefully pull sealing flange with fuel line -2- as far as possible
out of opening in fuel tank.

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Passat and Arteon:

– Pull fuel delivery unit -2- as far as possible out of fuel tank.
– Grip through opening in fuel tank.
– Release fuel line -1- in fuel tank and pull it off from line -3-.
Separate plug-in connectors ⇒ page 80 .
Continued for all vehicles:
– Carefully pull out fuel delivery unit with fuel gauge sender - G-
through opening of fuel tank.
– Turn and tilt it as necessary while doing so.
– When removing fuel delivery unit, ensure that float arm is not
bent.
– Place a cloth underneath the fuel delivery unit to catch any
escaping fuel.

Note

♦ When the delivery unit is replaced, the old delivery unit must
emptied before disposal.
♦ Observe environmental regulations for disposal.
♦ Check fuel tank for foreign bodies and dirt.

Installing
Install in reverse order of removal. The following should be ob‐
served:

Note

♦ Make sure all components are mounted in the correct position.

♦ Separate plug-in connectors ⇒ page 80 .

– Renew seal.
– Insert seal for fuel delivery unit dry into opening of fuel tank.
– When inserting fuel delivery unit, ensure that fuel gauge send‐
er is not bent.

– Coat inner side of seal -1- with fuel.

– Push flange downwards against spring force and move flange
into installation position.
– Observe installation position of fuel delivery unit ⇒ page 58 .
– When flange is inserted, ensure that seal is not damaged or
squashed.

3. Fuel delivery unit, fuel gauge sender 67

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– Tighten locking ring using wrench - T10202- .

– Push fuel lines -1- and -2- onto flange until they engage audi‐
bly.
– If featured, install fuel line -3- leading to metering pump - V54-
for auxiliary heater on sealing flange ⇒ page 120 .

– Connect connectors -1- and -2-.

– If fitted, connect and attach connector -3- for metering pump -
V54- of auxiliary heater at flange.
– Check connectors are secured properly by pulling.
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .
Specified torques
♦ ⇒ “3.1 Assembly overview - fuel delivery unit/fuel gauge send‐
er”, page 56

3.2.2 Removing and installing fuel delivery

unit/fuel gauge sender, vehicles with
four-wheel drive
Special tools and workshop equipment required
♦ Special wrench - T10202-

68 Rep. gr.20 - Fuel supply system

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♦ Torque wrench - V.A.G 1332-

♦ Removal wedge - 3409-

Removing
– The fuel tank must not be more than 3/4 full. This ensures that
the fill level is below the flange of the fuel delivery unit.
– If necessary, drain fuel tank ⇒ page 41 .
– Move front seats to foremost position.
– Switch off ignition.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .
– Remove cover of assembly opening on right or centre
⇒ page 77 .
– Release and pull off electrical connectors -1- and -2- on flange.
Vehicles with auxiliary heater:
– Detach connector -3- for metering pump - V54- from sealing
flange.
– Release and pull off connector -3- for metering pump - V54- .
Continued for all vehicles:
– Remove fuel pump control unit - J538- with wiring harness still
attached ⇒ page 111 .
– Guide fuel pump control unit - J538- out towards interior be‐
tween fuel tank and floor panel.
– Place fuel pump control unit - J538- together with wiring har‐
ness to one side.

3. Fuel delivery unit, fuel gauge sender 69

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– Disconnect fuel return line -1- at sealing flange. Separate plug-

in connectors ⇒ page 80 .

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

– Disconnect fuel return line -2- at flange. Separate plug-in con‐

nectors ⇒ page 80 .
Vehicles with auxiliary heater:
– Detach fuel line -3- leading to metering pump - V54- for aux‐
iliary heater from sealing flange ⇒ page 121 .

Continued for all vehicles:

– Open locking ring using wrench - T10202- .

– Carefully lift up flange -3-.

– Pull sealing flange -3- for a short distance out of the opening
in the fuel tank.
– Remove seal -1- at the opening in the fuel tank.
– Carefully pull sealing flange with fuel line -2- as far as possible
out of opening in fuel tank.

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– Grip through opening in fuel tank.

– Press release buttons -arrow A- on connection piece -2-. Sep‐
arate plug-in connectors ⇒ page 80 .
– Pull line -3- off line -1-.
– Push fastener -arrow B- upwards, and pull slide upwards.
– Disconnect line -4-.
– Carefully pull out fuel delivery unit with fuel gauge sender - G-
through opening of fuel tank.
– Turn and tilt fuel delivery unit as necessary while doing so.
– When removing fuel delivery unit, ensure that float arm is not
bent.
– Place a cloth underneath the fuel delivery unit to catch any
escaping fuel.

Note

♦ When the delivery unit is replaced, the old delivery unit must
emptied before disposal.
♦ Observe environmental regulations for disposal.
♦ Check fuel tank for foreign bodies and dirt.

Installing
Install in reverse order of removal. The following should be ob‐
served:
– Make sure all components are mounted in the correct position.
– Renew seal.
– Observe installation position of fuel extractor line for auxiliary
heater ⇒ page 120 .
– Ensure that connectors and lines are secured properly to fuel
delivery unit by pulling on them.
– Insert seal for fuel delivery unit dry into opening of 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 sealing flange -2- downwards against spring force and
bring it into installation position.
– Note installation position of flange when installing
⇒ page 61 .
– When flange is inserted, ensure that seal is not damaged or
squashed.

3. Fuel delivery unit, fuel gauge sender 71

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– Tighten 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.

– Push fuel lines -1- and -2- onto flange until they engage audi‐
bly.
– If fitted, install fuel line -3- to metering pump - V54- for auxiliary
heater on sealing flange ⇒ Auxiliary heater; Rep. gr. 82 ; Fuel
supply system; Overview of fitting locations – fuel supply sys‐
tem .
– Ensure fuel lines are secured properly by pulling.

– Connect connectors -1- and -2-.

– If fitted, connect and attach connector -3- for metering pump -
V54- of auxiliary heater at flange.
– Check connectors are secured properly by pulling.
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .
Specified torques
♦ ⇒ “3.1 Assembly overview - fuel delivery unit/fuel gauge send‐
er”, page 56

3.3 Removing and installing fuel gauge

sender - G-
⇒ “3.3.1 Removing and installing fuel gauge sender G , vehicles
with front-wheel drive”, page 72
⇒ “3.3.2 Removing and installing fuel gauge sender G , vehicles
with four-wheel drive”, page 73

3.3.1 Removing and installing fuel gauge

sender - G- , vehicles with front-wheel
drive
Removing
– Remove fuel delivery unit ⇒ page 64 .

72 Rep. gr.20 - Fuel supply system

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– Release and pull off connector -2- on sealing flange.

– Detach electrical wires from retainer -arrows A- and move to
side.
– Release catches -1- and -3-.
– To do this, press catches in -direction of arrow B-.
– Push out fuel gauge sender - G- upwards in direction of
-arrow C-.
Installing
Install in reverse order of removal. The following should be ob‐
served:
– Insert fuel gauge sender - G- into guides on fuel delivery unit
and press down until it engages.
– Check connectors are secured properly by pulling.
– Route and attach wires on fuel delivery unit.
– Install fuel delivery unit ⇒ page 64 .

3.3.2 Removing and installing fuel gauge

sender - G- , vehicles with four-wheel
drive
Removing
– Remove fuel delivery unit ⇒ page 64 .
– Release and pull off electrical connector -3- on sealing flange
-4-.
– Detach and move clear electrical wiring at retainer.
– Release catches -2-.
– To do this, press catches in direction of -arrow A-.
– Push out fuel gauge sender - G- -1- upwards in direction of
-arrow B-.
Installing
Install in reverse order of removal. The following should be ob‐
served:
– Insert fuel gauge sender - G- into guides on fuel delivery unit
and press down until it engages.
– Check connectors are secured properly by pulling.
– Route and attach wires on fuel delivery unit.
– Install fuel delivery unit ⇒ page 64 .

3.4 Removing and installing fuel gauge

sender 2 - G169-
Special tools and workshop equipment required

3. Fuel delivery unit, fuel gauge sender 73

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♦ Special wrench - T10202-

♦ Torque wrench - V.A.G 1332-

♦ Removal wedge - 3409-

Removing
– The fuel tank must not be more than 3/4 full. This ensures that
the fill level is below the flange of the fuel delivery unit.
– If necessary, drain fuel tank ⇒ page 41 .
– Move front seats to foremost position.
– Switch off ignition.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .
– Remove assembly opening cover on left ⇒ page 77 .

74 Rep. gr.20 - Fuel supply system

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– Release and pull off connector -2- on sealing flange.

– Release and pull off connector -1- on sealing flange.
– If fitted, release and pull off electrical connector -3- on flange.
– Unclip electrical connectors from mountings on flange.

– Open locking ring using wrench - T10202- .

– Carefully lift sealing flange -2- and pull it out of opening in fuel
tank.
– Unclip suction-jet pump -1- from fuel gauge sender 2 - G169- .
– To do so, carefully bend retaining lugs -arrows- outwards.
– Place a cloth underneath to absorb fuel.
– Carefully pull out fuel gauge sender 2 - G169- through opening
in fuel tank.
– Turn and tilt it as necessary while doing so.

Note

When removing, ensure that the float arm of the fuel gauge send‐
er 2 - G169- is not bent.

3. Fuel delivery unit, fuel gauge sender 75

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– Release connector -3- from unit -2- and pull off connector.
– Thread out electrical wiring.
– Release fuel gauge sender 2 - G169- -1- from unit -2-.
– To do so, carefully bend open retaining lugs -arrows-.
– Pull off fuel gauge sender 2 - G169- in -direction of arrow-.

Note

♦ Observe environmental regulations for disposal.

♦ Check fuel tank for foreign bodies and dirt.

Installing
Install in reverse order of removal. The following should be ob‐
served:

Note

♦ Make sure all components are mounted in the correct position.

♦ Ensure that the electrical wiring is correctly routed in the
mountings.

– Renew seal.
– Ensure fuel gauge sender 2 - G169- is firmly seated by pulling.

Passat and Arteon:

– Coat inner side of seal -3- with fuel.
– Install suction-jet pump -1-.
– When inserting fuel gauge sender 2 - G169- -2-, ensure that
sender arm is not bent.
– Ensure that fuel gauge sender 2 - G169- is installed in position
as shown.

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Tiguan:
– Coat inner side of seal -3- with fuel.
– Install suction-jet pump -1-.
– When inserting fuel gauge sender 2 - G169- -4-, ensure that
sender arm is not bent.
– Ensure that fuel gauge sender 2 - G169- is installed in position
as shown.

Continued for all vehicles:

– Push flange downwards against spring force and move flange
into installation position.
– Note installation position ⇒ page 63 .
– When flange is inserted, ensure that seal is not damaged or
squashed.
– Tighten locking ring using wrench - T10202- .
– Check connectors are secured properly by pulling.
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .
Specified torques
♦ ⇒ “3.1 Assembly overview - fuel delivery unit/fuel gauge send‐
er”, page 56

3.5 Removing and installing assembly

opening cover
⇒ “3.5.1 Removing and installing assembly opening cover, Passat
and Arteon”, page 77
⇒ “3.5.2 Removing and installing assembly opening cover, Ti‐
guan”, page 78

3.5.1 Removing and installing assembly

opening cover, Passat and Arteon
Special tools and workshop equipment required

3. Fuel delivery unit, fuel gauge sender 77

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♦ Removal wedge - 3409-

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

Rep. gr. 72 ; Rear seats; Removing and installing bench seat /
individual seats .
– Unclip cover -1- for flange at retaining tabs -arrows-, using re‐
moval wedge - 3409- .

– Unclip sealing grommet -1- downwards from cover -2-.

– Push cover -2- back along wiring harness -3-.

3.5.2 Removing and installing assembly

opening cover, Tiguan
Special tools and workshop equipment required
♦ Removal wedge - 3409-

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– Remove rear seats ⇒ General body repairs, interior; Rep. gr.

72 ; Rear seats; Removing and installing bench seat / individ‐
ual seats .
– Fold up floor covering and support in this position ⇒ General
body repairs, interior; Rep. gr. 70 ; Interior trim .
– Unclip cover -1- for sealing flange at retaining tabs -arrows-.
– Unclip sealing grommet -2- downwards from cover -1-.
– Move cover -1- towards rear along wiring harness.

3. Fuel delivery unit, fuel gauge sender 79

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4 Plug-in connectors
⇒ “4.1 Separating plug-in connectors”, page 80

4.1 Separating plug-in connectors

Special tools and workshop equipment required
♦ 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 of the respective colour
⇒ page 80 .
♦ Plug-in connectors for fuel lines must engage »audibly« when
joined.
♦ Ensure plug-in connector is secured properly by pulling it.

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

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

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Note

Bear in mind that the fuel pump can be activated due to opening
of a door with the battery connected. Fuel can escape if the sys‐
tem has been opened.

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

Open
Counterhold at the coupling point for fuel -1- in the engine com‐
partment.
– Insert lever - T10468- between heat shield and stop -arrow- of
fuel line -2- and counterhold.

Continuation for all connections in 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-.
Note colour assignment during installation ⇒ page 80 .
Plug-in connectors for fuel lines must engage »audibly« when
joined.
– Ensure plug-in connector is secured properly by pulling it.

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

Open
– Push plug-in connector -1- in -direction of arrow A-.
– Pull pull-release mechanism -2- in -direction of arrow B-.
– Pull plug-in connector -1- off fuel line -3- in
-direction of arrow B-.
Note colour assignment during installation ⇒ page 80 .
Plug-in connectors for fuel lines must engage »audibly« when
joined.
– Ensure plug-in connector is secured properly by pulling it.

Version 3
Plug-in connector with button in front -arrow-
Open
– Press release button -arrow- and pull off plug-in connectors.
Note colour assignment during installation ⇒ page 80 .
Plug-in connectors for fuel lines must engage »audibly« when
joined.
– Ensure plug-in connectors are secure properly by pulling.

Version 4
Plug-in connector with release button -arrows- on right and left:
Open
– Push plug-in connector in -direction of arrow A-.
– Press release buttons -arrows- and pull off plug-in connector.
Note colour assignment during installation ⇒ page 80 .
Plug-in connectors for fuel lines must engage »audibly« when
joined.
– Ensure plug-in connector is secured properly by pulling it.

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Version 5
Plug-in connector with release buttons -arrows- on right and left:
Open
Note colour assignment during installation ⇒ page 80 .
– Press release buttons -arrows- and pull off plug-in connector.
Note colour assignment during installation ⇒ page 80 .
Plug-in connectors for fuel lines must engage »audibly« when
joined.
– Ensure plug-in connector is secured properly by pulling it.

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.
– Press release buttons -arrows- and pull off plug-in connector.
Note colour assignment during installation ⇒ page 80 .
Plug-in connectors for fuel lines must engage »audibly« when
joined.
– Ensure plug-in connector is secured properly by pulling it.

Version 7
Plug-in connector -1- with release buttons -2- on right and left:
Open
– Press plug-in connector -1- in -direction of arrow A- and main‐
tain pressure.
– Press release button -2- in -direction of arrow B- and pull off
plug-in connector -1-.
Note colour assignment during installation ⇒ page 80 .
Plug-in connectors for fuel lines must engage »audibly« when
joined.
– Ensure plug-in connector is secured properly by pulling it.

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.

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5 Fuel filter
⇒ “5.1 Assembly overview - fuel filter”, page 84
⇒ “5.2 Removing and installing fuel filter”, page 87
⇒ “5.3 Fuel hoses in the engine compartment”, page 90
⇒ “5.4 Drain water from fuel filter”, page 90

5.1 Assembly overview - fuel filter

⇒ “5.1.1 Assembly overview - fuel filter”, page 84
⇒ “5.1.2 Assembly overview - fuel filter, vehicles with water sep‐
arator sender G63 ”, page 86

5.1.1 Assembly overview - fuel filter

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.
♦ Diesel fuel sold in the winter is guaranteed to be capable of filtration down to -20 °C.
♦ Test a sample, if unsure in winter. Expose sample to low ambient temperature for approx. 1 hour. 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.

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1 - Fuel filter
❑ Removing and installing
⇒ page 87
❑ Observe notes refer‐
ence fuel hoses in the
engine compartment
⇒ page 90 .
2 - Filter element
❑ Removing and installing
⇒ Maintenance ; Book‐
let 821
❑ To do this, remove and
install the upper part of
fuel filter ⇒ page 89 .
3 - Upper part of fuel filter
❑ With connections
❑ Removing and installing
⇒ page 89
❑ Observe notes refer‐
ence fuel hoses in the
engine compartment
⇒ page 90 .
4 - Bolt
❑ Qty. 5
❑ 5 Nm
5 - Bolt
❑ Qty. 2
❑ 8 Nm
6 - Nut
❑ 8 Nm
7 - Connection
❑ Observe notes refer‐
ence fuel hoses in the engine compartment ⇒ page 90 .
❑ Fuel supply from fuel tank
❑ Separate plug-in connectors ⇒ page 80 .
8 - Connection
❑ Fuel supply to high-pressure pump
❑ Observe notes reference fuel hoses in the engine compartment ⇒ page 90 .
❑ Separate plug-in connectors ⇒ page 80 .
9 - Connection
❑ Observe notes reference fuel hoses in the engine compartment ⇒ page 90 .
❑ Fuel return line from fuel rail and from fuel return lines of injectors to fuel filter
❑ Separate plug-in connectors ⇒ page 80 .

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5.1.2 Assembly overview - fuel filter, vehicles with water separator sender - G63-

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.
♦ 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.
♦ Diesel fuel sold in the winter is guaranteed to be capable of filtration down to -20 °C.
♦ Test a sample, if unsure in winter. Expose sample to low ambient temperature for approx. 1 hour. 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.

1 - Bolt
❑ Qty. 5
❑ 5 Nm
2 - Fuel hose
❑ Fuel return line from fuel
rail and from fuel return
lines of injectors to fuel
filter
❑ Observe notes refer‐
ence fuel hoses in the
engine compartment
⇒ page 90 .
❑ Note that the fuel lines
may be connected to the
fuel filter in different
ways
3 - Fuel hose
❑ Fuel supply to high-
pressure pump
❑ Observe notes refer‐
ence fuel hoses in the
engine compartment
⇒ page 90 .
❑ Note that the fuel lines
may be connected to the
fuel filter in different
ways
4 - Fuel hose
❑ Fuel supply from fuel
tank
❑ Observe notes refer‐
ence fuel hoses in the
engine compartment
⇒ page 90 .
❑ Disconnect plug-in con‐
nectors ⇒ page 80
❑ Note that the fuel lines may be connected to the fuel filter in different ways
5 - Upper part of fuel filter
❑ With connections

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❑ Removing and installing ⇒ page 89
❑ Observe notes reference fuel hoses in the engine compartment ⇒ page 90 .
6 - Filter element
❑ Removing and installing ⇒ Maintenance ; Booklet 821
❑ To do this, remove and install the upper part of fuel filter ⇒ page 89 .
7 - Water separator sender - G63-
❑ Removing and installing ⇒ page 115
8 - Seal
9 - Nut
❑ 5 Nm
10 - Bolt
❑ Qty. 2
❑ 8 Nm
11 - Guide bush
❑ Locks fuel filter in place on pin at engine mounting
12 - Fuel filter housing
❑ Removing and installing ⇒ page 87
❑ Observe notes reference fuel hoses in the engine compartment ⇒ page 90 .
13 - Water drain screw
❑ 8 Nm

5.2 Removing and installing fuel filter

Special tools and workshop equipment required
♦ Hose clamp pliers - V.A.G 1921-

Removing
– Observe notes reference fuel hoses in the engine compart‐
ment ⇒ page 90 .
– Switch off ignition.

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If the fuel filter is only to be removed to make space:

– Pull off fuel supply lines -1- and -2-. Separate plug-in connec‐
tors ⇒ page 80 .
– Unclip fuel lines -1- and -2- from retainer -arrow- on coolant
expansion tank -3-.

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

Vehicles with SCR system:

– Unclip, release and pull off connector -3-.
– Unclip retainer for electrical connector.

Continued for all vehicles:

– Remove bolts -2-.
– Unscrew nut -1-.

– Open retainer -arrow- and unclip fuel lines -1-.

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Vehicles with water separator sender - G63- :

– Raise fuel filter -1-.
– Release and pull off connector -2- on bottom.
– Then, lay fuel filter to one side.

If the fuel filter is to be opened:

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

If the fuel filter is to be renewed:

– Remove fuel hoses -3- to -5-.
– To do so, release hose clips using hose clip pliers - V.A.G
1921- .
– Unscrew bolts -2-.
– Unscrew nut -1-.
– Detach fuel filter housing.
– Collect any escaping fuel.
Installing
Install in reverse order of removal. The following should be ob‐
served:

Note

♦ Observe notes reference fuel hoses in the engine compart‐

ment ⇒ page 90 .
♦ Secure hose connections with hose clips in such a way that
factory standard is restored ⇒ Electronic parts catalogue

– Bleed fuel system ⇒ Rep. gr. 23 ; Injection system; Filling/

bleeding fuel system .
Specified torques
♦ ⇒ “5.1 Assembly overview - fuel filter”, page 84

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5.3 Fuel hoses in the engine compartment

Note

♦ The connections for the fuel hoses on the fuel filter -1- and fuel
temperature sender -2- and the plug-in connectors have a 2-
ribbed section -arrows- and a bite edge.
♦ This reduces the likelihood of fuel system 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, this leads to leaks in the fuel system.
♦ If the fuel filter only has to be removed to gain space, leave
the fuel hoses on the fuel filter and high-pressure pump. Place
the fuel filter with the hoses connected on the engine to avoid
having to renew them unnecessarily.
♦ Disconnect at other fuel system connection points in the en‐
gine compartment ⇒ page 88 .
♦ Separate plug-in connectors ⇒ page 80 .
♦ After removing fuel hoses from connections with a 2 wave
profile section and engagement lip, these fuel hoses must be
replaced.
♦ Never insert a screwdriver or similar tool between the hose
and the connection! Risk of damage to the connection - com‐
ponent must be renewed.

– Turn fuel hose with suitable pliers and pull off hose.
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.

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.

5.4 Drain water from fuel filter

Special tools and workshop equipment required

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♦ Ratchet wrench - V.A.G 1331/1-

♦ Torque wrench - V.A.G 1331-

Note

Please observe disposal instructions!

– Fit a suitable hose onto water drain plug -1-.

– Start engine.
– Carefully loosen water drain plug -1- until water escapes. Col‐
lect any escaping fluid in a suitable container.
The water is drained from the fuel filter due the system pressure.
– When diesel fuel escapes, tighten water drain plug, and pull
off hose.
– Tighten water drain plug to specified torque.
Specified torque
♦ Water drain plug ⇒ Item 13 (page 87)

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6 Accelerator pedal
⇒ “6.1 Assembly overview - accelerator module”, page 92
⇒ “6.2 Removing and installing accelerator pedal module GX2 ”,
page 93

6.1 Assembly overview - accelerator module

1 - Bolt
❑ 6 Nm
2 - Electrical connector
❑ Make sure connectors
are attached properly;
pull to check that they
are correctly engaged.
3 - Gas pedal module - GX2-
❑ Includes
Acceleration pedal posi‐
tion sender - G79-

Accelerator position
sender 2 - G185-
❑ Removing and installing
⇒ page 93

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6.2 Removing and installing accelerator

pedal module - GX2-
Removing
– Fold floor covering -1- forwards in -direction of arrow-.

– Release and pull off connector -2- at accelerator module.

– Unscrew bolt -1-.
– Detach accelerator pedal module -3- from mounting.
Installing
Install in reverse order of removal. The following should be ob‐
served:
Specified torques
♦ ⇒ “6.1 Assembly overview - accelerator module”, page 92

6. Accelerator pedal 93
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7 Fuel pump
⇒ “7.1 Checking fuel system pressurisation pump G6 ”,
page 94
⇒ “7.2 Removing and installing suction-jet pump”, page 107
⇒ “7.3 Removing and installing fuel pump control unit J538 ”, page
111
⇒ “7.4 Checking suction-jet pump”, page 114

7.1 Checking fuel system pressurisation

pump - G6-
⇒ “7.1.1 Checking fuel pressure”, page 94
⇒ “7.1.2 Checking fuel delivery rate”, page 100

7.1.1 Checking fuel pressure

Special tools and workshop equipment required
♦ Pressure gauge - VAS 6551-

♦ Adapter set - VAS 6551/5-

♦ Hose clamp pliers - V.A.G 1921-

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♦ Removal wedge - 3409-

♦ Vehicle diagnosis and service information system

Note

Bear in mind that the fuel pump can be activated due to opening
of a door with the battery connected. Fuel can escape if the sys‐
tem has been opened.

Test conditions:
• Connect battery charger, battery voltage at least 12.5 volts ⇒
Electrical system; Rep. gr. 27 ; Battery; Charging battery .
• Fuses OK. ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
• Fuel pump control unit - J538- OK ⇒ Vehicle diagnostic tester.
• Fuel filter OK.
• Ensure that vehicle is placed on a level surface.
• Fuel tank at least 1/2 full.
• All electrical consumers, e.g. lights and rear window heating,
must be switched off.

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.
♦ Diesel fuel sold in the winter is guaranteed to be capable of
filtration down to -20 °C.
♦ Test sample, if unsure in winter.
♦ Expose sample to low ambient temperature for approx. 1 hour.
♦ 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.

Test sequence
– Switch off ignition.

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– Remove engine cover ⇒ Rep. gr. 10 ; Engine cover; Remov‐

ing and installing engine cover .
Vehicles with engine code CUAA:
– Remove fuel supply line coming from fuel filter -1- from fuel
temperature sender - G81- ⇒ Rep. gr. 23 ; Senders and sen‐
sors; Removing and installing fuel temperature sender G81 .
– Connect a suitable, commercially available hose between con‐
nection -B- of diesel pressure tester - VAS 6551- and free
connection on fuel temperature sender - G81- .
– Secure hose with clips.
– Connect connecting line - VAS 6551/5-3- between connection
-A- of pressure tester - VAS 6551- and fuel supply line -1- from
fuel filter.
– Secure connecting line - VAS 6551/5-3- to fuel supply line us‐
ing a clip.

Vehicles with all other engine codes:

– Open clamp -arrow-.

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

– Pull fuel supply line -1- off high-pressure pump -2-.

– 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
a clip.

CAUTION
Risk of fire due to escaping fuel.
Risk of severe injuries and burns.
– Before testing, check all connected lines for secure fit by
pulling.
– Take any fuel-soaked cloths away from area of vehicle.

Continued for all vehicles:

– Switch on pressure tester - VAS 6551- by pressing On/Off
button.

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– Ensure that drain tap -C- on pressure tester - VAS 6551- -1-
is closed.
– Shut-off valves -A- and -B- on pressure tester - VAS 6551-
-1- are open.
– Connect ⇒ Vehicle diagnostic tester.
– Select function 0001 Activate fuel pump .
– Select function Check fuel pump delivery pressure/de-
livery rate .

– Follow instructions on ⇒ Vehicle diagnostic tester.

Note

The fuel pump is now activated.

– 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:

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

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

⇒ page 80 .

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– 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
Risk of fire due to escaping fuel.
Risk of severe injuries and burns.
– Before testing, check all connected lines for secure fit by
pulling.
– Take any fuel-soaked cloths away from area of vehicle.

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

button.

– Ensure that drain tap -C- on pressure tester - VAS 6551- -1-
is closed.
– Shut-off valves -A- and -B- on pressure tester - VAS 6551-
-1- are open.
– Repeat function Checking fuel pump delivery pressure/
delivery rate ⇒ page 97 .

If specification is now obtained:

Check fuel filter, renew if necessary ⇒ page 84 .
If specification is not obtained
Proceed as follows to check fuel pressure at fuel delivery unit:
Checking fuel pressure on fuel delivery unit:
– Remove cover of assembly opening on right or centre
⇒ page 77 .

– If fitted, unclip connector -3- for metering pump - V54- at fuel

delivery unit.
– Remove fuel pump control unit - J538- with wiring harness still
attached ⇒ page 111 .
– Guide fuel pump control unit - J538- out towards interior be‐
tween fuel tank and floor panel.
– Place fuel pump control unit - J538- together with wiring har‐
ness to one side.

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– Release fuel supply line -1- and pull it off sealing flange. Sep‐
arate plug-in connectors ⇒ page 80 .

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

– Connect pressure tester - VAS 6551/5-3- and fuel supply line

-2- leading to fuel filter by means of hose - VAS 6551- .
– Connect hose - VAS 6551/5-4- between pressure tester - VAS
6551- and fuel delivery unit -1-.

CAUTION
Risk of fire due to escaping fuel.
Risk of severe injuries and burns.
– Before testing, check all connected lines for secure fit by
pulling.
– Take any fuel-soaked cloths away from area of vehicle.

– Ensure that drain tap -C- on pressure tester - VAS 6551- -1-
is closed.
– Shut-off valves -A- and -B- on pressure tester - VAS 6551-
-1- are open.
– Repeat function Checking fuel pump delivery pressure/
delivery rate ⇒ page 97 .

If reading matches specification:

– Check fuel lines leading to engine for possible restrictions
(kinks), blockages and damages.
– Check fuel lines for leaks.
If specification is not obtained
– Remove fuel delivery unit ⇒ page 64 .
– Check filter strainer for soiling.
– Check that all electrical wires are connected correctly.
– Pull on connectors to check they are firmly seated
⇒ page 64 .

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– 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 64 .

7.1.2 Checking fuel delivery rate

Special tools and workshop equipment required
♦ Pressure gauge - VAS 6551-

♦ Adapter set - VAS 6551/5-

♦ Removal wedge - 3409-

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♦ Hose clamp pliers - V.A.G 1921-

♦ Pressure regulating valve - VAS 6551/6-

♦ Vehicle diagnosis and service information system

♦ Measuring container, capacity at least 3 litres

Note

Bear in mind that the fuel pump can be activated due to opening
of a door with the battery connected. Fuel can escape if the sys‐
tem has been opened.

Test conditions:
• Connect battery charger, battery voltage at least 12.5 volts ⇒
Electrical system; Rep. gr. 27 ; Battery; Charging battery .
• Fuses OK. ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
• Fuel pump control unit - J538- OK ⇒ Vehicle diagnostic tester.
• Fuel filter OK.
• Fuel tank at least 1/2 full.
• Ensure that vehicle is placed on a level surface.
• All electrical consumers, e.g. lights and rear window heating,
must be switched off.
• Fuel pressure OK ⇒ page 94 .

7. Fuel pump 101

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Note

♦ The vehicle must be fuelled with the diesel fuel appropriate for
the time of the year. Summer diesel may coagulate (flock) in
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.
♦ Diesel fuel sold in the winter is guaranteed to be capable of
filtration down to -20 °C.
♦ Test a sample, if unsure in winter. Expose sample to low am‐
bient temperature for approx. 1 hour. If the diesel fuel coagu‐
lates 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.

– Switch off ignition.

– Remove engine cover ⇒ Rep. gr. 10 ; Engine cover; Remov‐
ing and installing engine cover .
Vehicles with engine code CUAA:
– Remove fuel supply line coming from fuel filter
⇒ Item 8 (page 85) from fuel temperature sender - G81- ⇒
Rep. gr. 23 ; Senders and sensors; Removing and installing
fuel temperature sender G81 .
– Connect connecting line - VAS 6551/5-3- between connection
-A- of pressure tester - VAS 6551- and fuel supply line -1- from
fuel filter.
– Secure connecting line - VAS 6551/5-3- to fuel supply line us‐
ing a clip.

Vehicles with all other engine codes:

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

– Open clamp -arrow- of fuel supply line -1-.

– Pull fuel supply line -1- off high-pressure pump -2-.

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– 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- .
Continued for all vehicles:
– Connect pressure regulator valve - VAS 6551/6- to connection
-B- of pressure tester - VAS 6551- .
– Hold end of hose of pressure regulating valve - VAS 6551/6-
in measuring container.

CAUTION
Risk of fire due to escaping fuel.
Risk of severe injuries and burns.
– Before testing, check all connected lines for secure fit by
pulling.
– Take any fuel-soaked cloths away from area of vehicle.
– Place measuring container down outside vehicle and ensure
that its base is secure.
– Have a second mechanic ensure that end of hose remains
in measuring container during test and measuring container
does not tip over.

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

button.

– Ensure that drain tap -C- on pressure tester - VAS 6551- -1-
is closed.
– Shut-off valves -A- and -B- on pressure tester - VAS 6551-
-1- are open.
– Connect ⇒ Vehicle diagnostic tester.
– Select function 0001 Activate fuel pump .
– Select function Check fuel pump delivery pressure/de-
livery rate .

– Follow instructions on ⇒ Vehicle diagnostic tester.

7. Fuel pump 103

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– 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-.
– Drain measuring container.
– Repeat function Checking fuel pump delivery pressure/
delivery rate .

Note

The fuel system pressurisation pump - G6- is now activated for

30 seconds.

– Check quantity delivered in measuring container.

• Specification: minimum quantity delivered 1100 cm3/30 s.
If the minimum delivery rate is not attained:
– 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 found:
Check fuel delivery rate before fuel filter as follows:
Checking fuel delivery rate ahead of fuel filter:

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

⇒ page 80 .

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

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– 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- .
– Connect pressure regulator valve - VAS 6551/6- to connection
-B- of pressure tester - VAS 6551- .
– Hold end of hose of pressure regulating valve - VAS 6551/6-
in measuring container.

CAUTION
Risk of fire due to escaping fuel.
Risk of severe injuries and burns.
– Before testing, check all connected lines for secure fit by
pulling.
– Take any fuel-soaked cloths away from area of vehicle.
– Place measuring container down outside vehicle and ensure
that its base is secure.
– Have a second mechanic ensure that end of hose remains
in measuring container during test and measuring container
does not tip over.

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

button.

– Ensure that drain tap -C- on pressure tester - VAS 6551- -1-
is closed.
– Shut-off valves -A- and -B- on pressure tester - VAS 6551-
-1- are open.
– Repeat function Checking fuel pump delivery pressure/
delivery rate ⇒ page 103 .

If the minimum delivery rate is now attained:

Check fuel filter, renew if necessary ⇒ page 84 .
If reading again does not match specification:
Proceed as follows to check fuel delivery rate at fuel delivery unit:
Checking fuel delivery rate on fuel delivery unit:
– Remove cover of assembly opening on right or centre
⇒ page 77 .

– Release fuel supply line -1- and pull it off sealing flange. Sep‐
arate plug-in connectors ⇒ page 80 .

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

7. Fuel pump 105

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– Connect hose - VAS 6551/5-4- to fuel supply line connection

on fuel delivery unit -1-.
– Connect hose - VAS 6551/5-4- to connection point -A- of pres‐
sure tester - VAS 6551- .
– Connect pressure regulator valve - VAS 6551/6- to connection
-B- of pressure tester - VAS 6551- .
– Hold end of hose of pressure regulating valve - VAS 6551/6-
in measuring container.

CAUTION
Risk of fire due to escaping fuel.
Risk of severe injuries and burns.
– Before testing, check all connected lines for secure fit by
pulling.
– Take any fuel-soaked cloths away from area of vehicle.
– Place measuring container down outside vehicle and ensure
that its base is secure.
– Have a second mechanic ensure that end of hose remains
in measuring container during test and measuring container
does not tip over.

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

button.

– Ensure that drain tap -C- on pressure tester - VAS 6551- -1-
is closed.
– Shut-off valves -A- and -B- on pressure tester - VAS 6551-
-1- are open.
– Repeat function Checking fuel pump delivery pressure/
delivery rate ⇒ page 103 .

If the minimum delivery rate is now attained:

– Check fuel lines for possible restrictions (kinks), blockages
and damages.
– Check fuel lines for leaks.
If reading again does not match specification:
– Remove fuel delivery unit ⇒ page 64 .
– 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 64 .

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7.2 Removing and installing suction-jet

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

♦ Torque wrench - V.A.G 1332-

♦ Removal wedge - 3409-

Removing
– Move front seats to foremost position.
– Switch off ignition.
– Remove rear bench seat ⇒ General body repairs, interior;
Rep. gr. 72 ; Rear seats; Removing and installing bench seat /
individual seats .
– Drain fuel tank ⇒ page 41 .
– Remove assembly opening cover on left and right
⇒ page 77 .
– Remove fuel delivery unit ⇒ page 68 .

7. Fuel pump 107

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– Release and pull off connector -2- on sealing flange.

– Release and pull off connector -1- on sealing flange.
– If fitted, release and pull off electrical connector -3- on flange.
– Unclip electrical connectors from mountings on flange.

– Open locking ring using wrench - T10202- .

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– Carefully lift sealing flange -2- and pull it out of opening in fuel
tank.
– Unclip suction-jet pump -1- from fuel gauge sender 2 - G169- .
– To do so, carefully bend retaining lugs -arrows- outwards.
– Place a cloth underneath to absorb fuel.
– Carefully pull out fuel gauge sender 2 - G169- through opening
in fuel tank.
– Turn and tilt it as necessary while doing so.

Note

When removing, ensure that the float arm of the fuel gauge send‐
er 2 - G169- is not bent.

– Pull suction-jet pump out through opening for fuel gauge send‐
er 2 - G169- in fuel tank.

Note

♦ Observe environmental regulations for disposal.

♦ Check fuel tank for foreign bodies and dirt.

Installing
Install in reverse order of removal. The following should be ob‐
served:

Note

♦ Make sure all components are mounted in the correct position.

♦ Separate plug-in connectors ⇒ page 80 .

– Renew seal.
– Insert suction-jet pump through left opening into fuel tank.
– Guide suction-jet pump towards fuel delivery unit.
– Grip through right opening in fuel tank.
– Clip delivery line to fuel delivery unit it engages audibly.
– Push on supply line for suction-jet pump until it engages au‐
dibly.
– Ensure that connectors and lines are secured properly to fuel
delivery unit by pulling on them.
– Install suction-jet pump to fuel gauge sender 2 - G169- .

7. Fuel pump 109

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Passat and Arteon:

– To do so, bend retaining lugs -arrows- open slightly and insert
suction-jet pump.
– Check firm seating by pulling.
– Insert seal for fuel delivery unit dry into opening of fuel tank.
– When inserting fuel gauge sender 2 - G169- , ensure that fuel
gauge sender is not bent.
– Ensure that fuel gauge sender 2 - G169- is installed in position
as shown.

Tiguan:
– To do so, bend retaining lugs -arrows- open slightly and insert
suction-jet pump.
– Check firm seating by pulling.
– Insert seal for fuel delivery unit dry into opening of fuel tank.
– When inserting fuel gauge sender 2 - G169- , ensure that fuel
gauge sender is not bent.
– Ensure that fuel gauge sender 2 - G169- is installed in position
as shown.
Continued for all vehicles:

– Insert dry seal -1- into opening on right of fuel tank.

– Coat inner side of seal -1- with fuel.
– Press down sealing flange -2- against spring pressure.
– Note installation position of flange ⇒ page 63 .

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– Tighten locking ring using wrench - T10202- .

– Fit connector on flange.
– Ensure that connectors and lines are secured properly to fuel
delivery unit by pulling on them.
Specified torques
♦ ⇒ “3.1 Assembly overview - fuel delivery unit/fuel gauge send‐
er”, page 56
♦ ⇒ “3.2.2 Removing and installing fuel delivery unit/fuel gauge
sender, vehicles with four-wheel drive”, page 68
♦ ⇒ “3.4 Removing and installing fuel gauge sender 2 G169 ”,
page 73

7.3 Removing and installing fuel pump con‐

trol unit - J538-
⇒ “7.3.1 Removing and installing control unit for fuel pump J538 ,
Passat and Arteon”, page 111
⇒ “7.3.2 Removing and installing fuel pump control unit J538 ,
Tiguan”, page 112

7.3.1 Removing and installing control unit for

fuel pump - J538- , Passat and Arteon
Special tools and workshop equipment required
♦ Removal wedge - 3409-

Removing
– Move front seats to foremost position.
– Switch off ignition.
– Remove cover of assembly opening ⇒ page 77 .

7. Fuel pump 111

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– Press up tab -2- in -direction of arrow A-; to do so, reach be‐

tween floor panel and fuel tank with your finger.
– At the same time, carefully pull fuel pump control unit - J538-
-1- out of mounting -in direction of arrow B- by grasping hold
of wiring harness -3-.
– Guide fuel pump control unit - J538- out towards interior be‐
tween fuel tank and floor panel.
– Unplug electrical connector and remove fuel pump control unit
- J538- .
Installing
Install in reverse order of removal. The following should be ob‐
served:
– Connect wiring harness to fuel pump control unit - J538- .
– Check if connector is secured properly by pulling it.
– Insert fuel pump control unit - J538- into mounting bracket on
fuel tank and push it in until it audibly engages.
– Pull on fuel pump control unit - J538- to make sure that it is
properly secured.

7.3.2 Removing and installing fuel pump con‐

trol unit - J538- , Tiguan
Special tools and workshop equipment required
♦ Removal wedge - 3409-

Removing
– Move front seats to foremost position.
– Switch off ignition.
All-wheel drive:
– Remove cover of assembly opening on right ⇒ page 77 .
Front-wheel drive:
– Remove cover of assembly opening in centre ⇒ page 77 .

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Continued for all vehicles:

– Press up tab -1- in direction of -arrow C-, reaching between
floor panel and fuel tank with a finger to do so.
– At same time, remove fuel pump control unit - J538- -2- from
mounting in direction of -arrow B- by carefully pulling on wiring
harness.
– Remove fuel pump control unit - J538- upwards by carefully
pulling on wiring harness.
– Guide fuel pump control unit - J538- out towards interior be‐
tween fuel tank and floor panel.
– Detach electrical connector and remove fuel pump control unit
- J538- .
– Guide fuel pump control unit - J538- out towards interior be‐
tween fuel tank and floor panel.
– Unplug electrical connector and remove fuel pump control unit
- J538- .
Installing
Install in reverse order of removal. The following should be ob‐
served:
– Connect wiring harness to fuel pump control unit - J538- .
– Check if connector is secured properly by pulling it.
– Insert fuel pump control unit - J538- into mounting bracket on
fuel tank and push it in until it audibly engages.
– Pull on fuel pump control unit - J538- to make sure that it is
properly secured.

7. Fuel pump 113

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7.4 Checking suction-jet pump

On vehicles with four-wheel drive the fuel tank is divided into a
left and a right chamber. Suction-jet pump -1- is used for deliver‐
ing fuel from the left fuel tank chamber -3- to the baffle housing
of the fuel delivery unit -2- on the right.
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

Note

♦ Risk of breakdown due to defective suction-jet pump.

♦ If the suction-jet pump is defective, the engine can stop due to
fuel starvation when the tank is still 1/4 full.

If the suction-jet pump is not functioning, approx. 15 litres of fuel

(1/4 of tank capacity) remain in the left chamber of the fuel tank.
This fuel cannot be extracted by the fuel delivery unit.
If the engine stops due to fuel starvation with the tank filled up to
about 1/4, proceed as follows:
– Check fuel system pressurisation pump - G6- ⇒ page 94 .
If fuel pump is OK, but no fuel is delivered:
– Refill fuel tank with approx. 5 litres of fuel.
– Start engine.
If engine starts OK now:
– Renew suction-jet pump ⇒ page 107 .

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8 Senders and sensors

⇒ “8.1 Removing and installing water separator sender G63 ”,
page 115

8.1 Removing and installing water separator

sender - G63-
Special tools and workshop equipment required
♦ Ratchet wrench - V.A.G 1331/1-

♦ Torque wrench - V.A.G 1331-

♦ Socket wrench - 3376-

♦ Commercially available 1/2 inch ratchet drive

♦ Commercially available 1/2 inch extension
Removing
– Remove and open fuel filter ⇒ page 87 .
– Remove filter insert ⇒ Maintenance ; Booklet 821 .
– Empty fuel filter.

8. Senders and sensors 115

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– Unscrew nut -3-.

– When doing this, counterhold on water separator sender -
G63- using socket - 3376- .
– Remove Water separator sender - G63- .
Installing:
– Ensure that seal -2- is correctly seated.
Specified torque:
♦ ⇒ “5.1.2 Assembly overview - fuel filter, vehicles with water
separator sender G63 ”, page 86

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

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9 Wiring
⇒ “9.1 Removing and installing fuel lines”, page 117
⇒ “9.2 Removing and installing fuel line for auxiliary/supplemen‐
tary heater”, page 120

9.1 Removing and installing fuel lines

Special tools and workshop equipment required
♦ Engine bung set - VAS 6122-

Vehicles with SCR system:

– Remove front part of reducing agent delivery line ⇒ Rep. gr.
26 ; SCR system (Selective Catalytic Reduction); Removing
and installing front part of reducing agent delivery line .
Continuation for all other vehicles
– Seal off all open lines and connections with clean plugs from
engine bung set - VAS 6122- .
– Remove underbody cladding on right side in front of rear axle
⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody
cladding; Assembly overview - underbody cladding .
– Detach underbody cladding on right side and lower ⇒ General
body repair, exterior; Rep. gr. 66 ; Underbody cladding; As‐
sembly overview - underbody cladding .
– Disconnect fuel lines on underbody ⇒ page 80 .
– Unclip retainer -1- on underbody -arrows-.
– Unclip bracket -1- from fuel lines.
– Secure a pulling aid (e.g. cable or cord) to fuel lines.
– The pulling aid eases reinstallation; choose an appropriate
length.
– Use adhesive tape to secure pulling aid.
– Lower vehicle using lifting platform.

9. Wiring 117
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– Pull off fuel supply lines -1- and -2-. Separate plug-in connec‐
tors ⇒ page 80 .

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

– Unclip fuel lines -1- and -2- from retainer -arrow- on coolant
expansion tank -3-.

– Disconnect electrical connector -1-.

– Remove coolant hoses from engine. To do this, open retain‐
ers.
– Using a screwdriver, release fasteners -arrow- and move cool‐
ant expansion tank to one side.
– Open refrigerant line retainers on right wheel housing.
– Unclip refrigerant lines ⇒ Heating, air conditioning; Rep. gr.
87 ; Refrigerant circuit; Removing and installing refrigerant
lines with internal heat exchanger .

Left-hand drive:
– If fitted, remove heat shield -1- on ABS hydraulic unit - N55- .
– To do this, unclip heat shield -1- from bracket -2- -arrow-.

Vehicles with auxiliary heater:

– Remove front part of wheel housing liner or front right wheel
housing liner ⇒ General body repairs, exterior; Rep. gr. 66 ;
Wheel housing liner; Assembly overview - front wheel housing
liner .
– Release and pull off fuel line -7-.
– Unclip fuel line from retainers, and guide it out.
– Unclip retainers for refrigerant lines from body ⇒ Heating, air
conditioning; Rep. gr. 87 ; Refrigerant circuit; Removing and
installing refrigerant lines with internal heat exchanger .
– Guide out fuel line from underneath refrigerant lines and en‐
gine mounting.

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Continued for all vehicles:

– Unclip shield -1- from stud on body -arrows-.
– Unclip shield -1- from longitudinal member -2-.
– If fitted, detach clip -4- for fuel line of auxiliary heater -3- from
body.
– Unclip retainer -2- for shield from longitudinal member.
– Pull out lines upwards.
– While doing this, just turn the lines carefully, do not jerk them.
– Unclip lines and remove shield upwards.
Installing:
– Detach pulling aid from old lines.
– Make sure that the sealing caps are properly seated on the
new lines.
– If necessary, seal open lines with suitable plugs from engine
bung set - VAS 6122- .

Note

♦ The fuel line, breather line and fuel line for auxiliary heater are
installed together.
♦ If necessary, use adhesive tape to fix the lines in position.

– Insert lines into guides on shield as shown in illustration, and

clip them in ⇒ page 119 .
– Do not clip in fuel lines in upper area of shield until after they
have been guided in ⇒ page 119 .
– Secure pulling aid to fuel lines.
– Use adhesive tape to secure pulling aid.
– Make sure that the pulling aid is only attached in the front area
of the lines.
– Close slotted guide at bottom area of shield with adhesive tape
to prevent lines from slipping out.
– Fit fuel lines together with shield to opening in longitudinal
member.

Installation position of lines on shield:

1- Fuel supply line
2- Fuel line for auxiliary heater
3- Guide for fuel line for auxiliary heater
4- Bottom line guide
5- Retainers for lines in area of coupling point
6- Return line
– Push in fuel lines collectively from front to rear.

9. Wiring 119
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– Clip lines into retainer on underbody -1-.

– Then clip retainer onto underbody

Installation position of fuel lines at coupling point in engine com‐

partment:
1- Fuel supply line
2- Breather line

Installation position of fuel lines on underbody:

2 - Breather line
3 - Fuel supply line
4 - Fuel line for auxiliary heater
Specified torques:
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liner; Assembly overview- front wheel housing liner
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody
cladding

9.2 Removing and installing fuel line for aux‐

iliary/supplementary heater
Removing
– The fuel tank must not be more than 3/4 full. This ensures that
the fill level is below the flange of the fuel delivery unit.
– Drain fuel tank ⇒ page 41 .
– Remove cover of assembly opening ⇒ page 77 .

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– Release and pull off connector -6- on sealing flange.

– Detach connector -6- for metering pump - V54- of auxiliary
heater on flange, and lay connector aside.

If the fuel line for metering pump - V54- is to be disconnected from

fuel delivery unit:
– Open lower clip -3- on flange -1-.

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

– Do not open upper clip -4-.

– Pull fuel line -2- together with grommet off flange.
If a new fuel delivery unit is installed:
– Remove fuel line ⇒ page 121 .

– Remove fuel delivery unit ⇒ page 64 .

– 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 64 .

9. Wiring 121
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Installing fuel line:

– Insert fuel line -3- in connection -5-.
– Insert fuel line to stop -arrow-.
– While doing this, fit grommet -1- over connection.
– Renew lower clip -4-.
– If the fuel line or grommet has been renewed, the upper clip
must be renewed as well.
– Renew clips -2- and -4-, if they have been opened.
– Secure hose connections with the hose clips corresponding to
original equipment.
Specified torques
♦ ⇒ “2.1 Assembly overview - fuel tank”, page 16

122 Rep. gr.20 - Fuel supply system