Volkswagen Golf Variant / Jetta. Manual - part 410

 

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Volkswagen Golf Variant / Jetta. Manual - part 410

 

 

1

Safety Precautions when Working on

Fuel Supply System

WARNING

When doing any assembly work, especially in the engine com‐

partment,  pay  attention  to  the  following  due  to  the  limited

space.

♦ Route all lines and wires in their original locations.
♦ For example, for fuel lines, hydraulic lines, EVAP system

lines, coolant and refrigerant lines, brake fluid lines and

vacuum lines.

♦ Make sure that there is sufficient clearance to all moving

or hot components.

♦ The fuel or fuel lines in fuel system can become very hot

(danger of scalding)!

♦ In addition, the fuel system is under pressure! Before

opening the system, place rags around the connection

area and release pressure by carefully loosening the con‐

nection!

♦ Always wear protective eyewear, safety gloves and pro‐

tective clothing when performing any work on the fuel

system to avoid eye injuries and burns.

♦ If fuel system components between the fuel tank and high

pressure fuel pump were removed or replaced, the fuel

system must be filled in order to bleed it. Refer to

⇒ “3.9 Fuel System, Filling/Bleeding”, page 328

 . (Run‐

ning the high pressure fuel pump when dry must always

be avoided).

Always Pay Attention to the following When Removing and In‐

stalling the Fuel Level Sensor - G- or the Fuel Pump - G23- (Fuel

Delivery Unit) From Full or Partially Filled Fuel Tanks.
♦ Before starting work, switch the exhaust extraction system on

and place an extraction hose close to the fuel tank installation

opening to extract fuel fumes. If no exhaust extraction system

is available, a radial fan (as long as motor is not in air flow)

with a delivery volume greater than 15 m

3

/h can be used.

♦ Do not let fuel come in contact with skin. Wear fuel-resistant

gloves.

1. Safety Precautions when Working on Fuel Supply System    

223

Guidelines for Clean Working Condi‐

tions

When Working on the Fuel Supply/Injection System, Pay Careful

Attention to the following “7 rules” of Cleanliness:
♦ Thoroughly clean the connection points and the surrounding

area before loosening.

♦ Place the removed parts on a clean surface and cover them.

Only use lint-free cloths.

♦ Carefully cover or seal opened components if the repair is not

performed immediately.

♦ Only install clean parts: remove the replacement parts from

their packaging just before installing them. Do not use parts

that have been loosely stored or unpackaged (for example, in

tool boxes etc.).

♦ Supplied transport and protective packaging and sealing cover

should only be removed immediately before installing.

♦ When the fuel system is open: avoid working with compressed

air if possible. Do not move the vehicle if possible.

♦ In addition, do not let diesel fuel flow onto the coolant hoses.

If necessary, the hoses must be cleaned again immediately.

Replace corroded hoses.

224

Misfueling

⇒ “3.1 Step 1 (Engine Was Started with Incorrect Fuel)”,

page 225
⇒ “3.2 Step 2 (Engine Was Not Started with Incorrect Fuel)”, page

226
⇒ “3.3 Step 3 (Shavings in the Fuel Delivery Unit and Reservoir)”,

page 227
⇒ “3.4 Step 4 (No Shavings in the Fuel Delivery Unit and Reser‐

voir)”, page 228
⇒ “3.5 Step 5 (Shavings in the High Pressure Pump)”,

page 228
⇒ “3.6 Step 6 (No Shavings in the High Pressure Pump)”,

page 229

Caution

Fueling incorrectly can cause insufficient lubrication which can

lead to irreversible damage to the high pressure components,

especially the high pressure pump. Damage caused by seizing

and particle abrasion should be expected. These particles will

cause further damage in the pressure control valve and the

injectors.

Note

This information guides the reader through the individual pro‐

cedures like a flowchart.

The connector couplings must »audibly« engage when lock‐

ing.

Note the color coding when installing the connector coupling.

Refer to 

⇒ page 245

 !

Pull on the connector coupling to check for secure fit.

Disconnect the connector couplings. Refer to

⇒ “5 Connector Couplings, Disconnecting”, page 245

 .

Was the Engine Started with the Incorrect Fuel?

Yes. Refer to

⇒ “3.1 Step 1 (Engine Was Started with Incorrect Fuel)”, page

225

 .

No. Refer to

⇒ “3.2 Step 2 (Engine Was Not Started with Incorrect Fuel)”,

page 226

 .

3.1

Step 1 (Engine Was Started with Incor‐

rect Fuel)

– Empty the fuel tank as much as possible through the filler neck

using the Fuel Extraction Unit - VAS5190- . Refer to

⇒ “4.4 Fuel Tank, Draining”, page 235

 .

– Remove the rear bench seat. Refer to ⇒  Body Interior; Rep.

Gr.  72 ; Rear Seats; Rear Bench Seat, Removing and Instal‐

ling .

– Remove the flange cover.

3. Misfueling    

225

Press the locking ring to release the fuel line.

WARNING

If the battery is connected, make sure that the fuel pump is not

activated when the door is opened. Fuel may leak out when

the system is open.

– Remove the fuel return line, which is blue or has a blue mark‐

ing, -1- from the fuel delivery unit. Disconnect the coupling.

Refer to

⇒ “5 Connector Couplings, Disconnecting”, page 245

 .

– Connect the Diesel Pressure Tester Kit - Adapter Set - Con‐

nection Hose 2 -VAS6551/5-2- to the fuel return line -1-.

– Guide the free end of the Diesel Pressure Tester Kit - Adapter

Set - Connection Hose 2 -VAS6551/5-2- into a suitable con‐

tainer.

– Connect the vehicle tester and perform the Guided Function

“Activate Fuel Pump (evacuate the fuel system)”.

Note

The fuel pump is now activated.

– Repeat this procedure as necessary until the fuel tank is com‐

pletely empty.

Remove the Fuel Delivery Unit. Refer to

⇒ “4.6 Fuel Delivery Unit, Removing and Installing”, page 241

 .

– Check the fuel tank for shavings.
– Empty the fuel delivery unit reservoir.
– Check the reservoir visually for large contaminants and shav‐

ings and on the screen.

Are There Any Shavings?

Yes. Refer to

⇒ “3.3 Step 3 (Shavings in the Fuel Delivery Unit and Reser‐

voir)”, page 227

 .

No. Refer to

⇒ “3.4 Step 4 (No Shavings in the Fuel Delivery Unit and Res‐

ervoir)”, page 228

 .

3.2

Step 2 (Engine Was Not Started with In‐

correct Fuel)

– Empty the fuel tank as much as possible through the filler neck

using the Fuel Extraction Unit - VAS5190- . Refer to

⇒ “4.4 Fuel Tank, Draining”, page 235

 .

– Remove the rear bench seat. Refer to ⇒  Body Interior; Rep.

Gr.  72 ; Rear Seats; Rear Bench Seat, Removing and Instal‐

ling .

– Fold the carpet to the side or forward if necessary.
– Remove the flange cover.

226

 

 

 

 

 

 

 

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