Fuel supply system components

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1 Volkswagen Touareg Fuel supply system components Page 1 / Fuel supply system components Caution! When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues: Route all the various lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum lines and hoses) and electrical wiring so that the original positions are restored. Ensure sufficient clearance to all moving or hot components. Note: Hose connections are secured with either springtype or clamp-type clips. Always replace clamp-type clips with spring-type clips. Fuel hoses at engine must only be secured with spring-type clips. The use of clamp or screw type clips is not permissible. Spring-type clip pliers VAS 5024 A or hose clip pliers V.A.G 1921 are recommended for installing spring-type clips. The fuel system must be bled if the fuel delivery unit

2 Page 2 / 47 is replaced 20-1, Fuel system, bleeding. Observe safety precautions 20-1, Safety precautions when working on fuel supply system. Observe rules for cleanliness cleanliness. 20-1, Rules for Fuel tank with attachments, assembly overview 20-1, Fuel tank with attachments, assembly overview. Fuel filter, assembly overview overview 20-1, Fuel filter, assembly Schematic diagram of fuel lines and components in fuel tank 20-1, Schematic diagram of fuel lines and components in fuel tank Fuel filter, replacing Fuel system, bleeding Fuel tank, emptying 20-1, Fuel filter, replacing 20-1, Fuel system, bleeding 20-1, Fuel tank, emptying Fuel delivery unit, fuel gauge sender and suction jet pump, removing and installing 20-1, Fuel delivery unit, fuel gauge sender and suction jet pump, removing and installing Fuel tank with attachments, removing and installing 20-1, Fuel tank with attachments, removing and installing Check fuel pumps 20-1, Fuel pumps, checking Parts of EVAP canister system: Vehicles with engine code BAA and BMX 20-3, Evaporative emissions (EVAP) system (vehicles with engine code BAA and BMX) Fuel tank with attachments, assembly overview Caution! During all repair procedures on the fuel tank, be aware of the following: Route all the various lines (e.g. for fuel, EVAP system, or vacuum) and electrical wiring so that the original routing positions are restored. Make sure that the Ground (GND) (-) strap between the fuel filler tube and body is securely

3 Page 3 / 47 fastened, to prevent electrostatic charging. Ensure sufficient clearance to all moving or hot components. Fuel filler tube With connection for Ground (GND) strap to body Ensure seated tightly To EVAP canister Fuel tank Support with engine/transmission jack V.A.G 1383 A when

4 Page 4 / 47 removing Fuel filter Disassembling and assembling 20-1, Fuel filter, assembly overview Locking ring, 145 Nm Use wrench T10202 for removal and installation Ensure seated tightly Fuel delivery unit Left side Check fuel pump 20-1, Fuel pumps, checking Fuel Level Sensor 3 G237 Left side Clipped into bottom of tank Suction jet pump Left side Clipped into bottom of tank Protective cover For bottom of fuel tank Securing strap Note installation position Ensure seated tightly 20 Nm + 1 / 4 turn (90 ) Protective cover For top of fuel tank

5 Page 5 / 47 Suction jet pump Right side Clipped into bottom of tank Fuel delivery unit Right side Check fuel pump 20-1, Fuel pumps, checking Fuel Gauge Sender G Right side Clipped into bottom of tank Flange Right side With fuel pressure regulator With gravity valve Individual components 20-1, Individual components of flange, right side Note installed position on fuel tank 20-1, Installed position of sender flange on fuel tank Vent line Ensure seated tightly Reservoir Gravity valve To pressure retaining valve

6 Page 6 / 47 Individual components of flange, right side 1 - Connections for Fuel Pump (FP) G23 and Fuel Level Sensor G 2 - Fuel pressure regulator (4 bar) 3 - Ground (GND) wire 4 - Pressure regulator inlet (from fuel filter) 5 - Connection to left and right-hand fuel pump units (no pressure) 6 - Gravity valve Installed position of sender flange on fuel tank - Insert sender flange with marking - arrow - in direction of travel. Fuel filter, assembly overview

7 Page 7 / 47 Connection For breather line Flange Left side With fuel filter housing Note installed position on fuel tank 20-1, Installed position of sender flange on fuel tank Filter element Oil seal Replace

8 Page 8 / 47 Ground (GND) wire Ensure seated tightly 10 Nm Supply line To fuel pressure regulator Connection Filter supply from left fuel pump unit Connection Filter supply from left fuel pump unit Ground (GND) connection Sealing cap For filter housing Locating pin Schematic diagram of fuel lines and components in fuel tank - A - Left side of tank - Arrow - indicates direction of travel - B - Right side of tank

9 Page 9 / 47 Gravity valve Left side Flange Left side Fuel filter Gravity valve Right side Supply line To fuel rail Supply line for auxiliary heater

10 Page 10 / 47 Flange Right side Fuel pressure regulator Return line From fuel pressure regulator To fuel delivery units on left and right sides Supply line for suction jet pump Fuel delivery unit Right side Suction jet pump Right side Delivery line Black To fuel delivery unit on left side Delivery line Black To fuel delivery unit on right side Suction jet pump Left side Fuel delivery unit Left side Safety precautions when working on fuel supply system

11 Page 11 / 47 Caution! During all repair procedures on the fuel tank, be aware of the following: Route all the various lines (e.g. for fuel, EVAP system, or vacuum) and electrical wiring so that the original routing positions are restored. Make sure that the Ground (GND) (-) strap between the fuel filler tube and body is securely fastened, to prevent electrostatic charging. Ensure sufficient clearance to all moving or hot components. For safety reasons, fuses and arrow - must be removed before opening fuel system because fuel pump can be activated by door contact switch in drivers door. Fuses 13 and 14 are located in fuse holder of electronic box in plenum chamber on left. Always observe the following when removing and installing the sender for fuel gauge or the fuel pump (fuel delivery unit) from full or partially filled fuel tanks: Warning! Fuel supply lines are under pressure! Wear eye protection and protective gloves to avoid injuries and skin contact with fuel. Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

12 Page 12 / 47 Already before starting work, switch on exhaust extraction system and place an extraction hose close to the sensor installation opening of fuel tank to extract escaping fuel fumes. If no exhaust extraction system is available, a radial fan (as long as motor is not in air flow) with a displacement greater than 15 m 3 /h can be used. Prevent fuel from contacting skin! Wear fuelresistant gloves! Rules for cleanliness When working on the fuel supply/injection system, pay careful attention to the following "5 rules" : Thoroughly clean all connections and the surrounding area before disconnecting. Place parts that have been removed on a clean surface and cover them. Do not use fluffy cloths! Carefully cover over opened components or seal, if repairs are not performed immediately. Only install clean components: Only unpack replacement parts immediately prior to installation. Do not use parts that have been stored loose (e.g. in tool boxes etc.). When the system is open: Avoid working with compressed air if possible. Do not move vehicle unless absolutely necessary. Fuel filter, replacing Special tools, testers and auxiliary items required

13 Page 13 / 47 Wrench T10202 Requirements The fuel tank must be drained 20-1, Fuel tank, emptying, emptying fuel tank. Fuses and arrows - must be removed from their sockets. Warning! Fuel supply lines are under pressure! Wear eye protection and protective gloves to avoid injuries and skin contact with fuel. Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection. Work procedure - Observe safety precautions before performing repair work 20-1, Safety precautions when working on fuel supply system.

14 Page 14 / 47 - Cut open carpet on left side from point - A - to point - B - in pre-cut area - arrow -. - Remove nuts from cover. If necessary, unbolt backrest support or support mounting. Repair Manual, Body Interior, Repair Group 72, Rear seats - Remove locking ring from left sender flange using fuel tank sender key T Remove flange from left side of tank. - Empty fuel filter housing.

15 Page 15 / 47 - Mark installation position of filter cover using colored felt tip marker pen. - Disconnect Ground (GND) wire and unbolt filter cover - arrows - from housing. If filter insert is to be replaced, ensure that the Ground (GND) connection contacts are not bent and have sufficient pretension. Fuel system, bleeding

16 Page 16 / 47 Special tools, testers and auxiliary items required Hose clamps up to 25 mm Ø 3094 Remote control connection V.A.G 1348/3A Diesel extractor VAS 5226 Not illustrated: Adapter V.A.G 1318/20 Adapter V.A.G 1318/20-1

17 Page 17 / 47 Adapter cable V.A.G 1348/3-3 Requirements Battery voltage must be at least 11.5 V. Fuel pump relays and for left and right fuel delivery units must be removed from their sockets. Work procedure - Observe safety precautions before performing repair work 20-1, Safety precautions when working on fuel supply system. - Remove cover in front of fuse holder. - Connect remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-3 to connection - arrow - for fuel pump relay for right fuel delivery unit. - Connect positive clamp of remote control to positive terminal in engine compartment.

18 Page 18 / 47 - Thread adapter V.A.G 1318/20-1 onto adapter V.A.G 1318/20. - Turn valve on T-piece - arrow - counter-clockwise until completely open. Warning! Fuel supply lines are under pressure! Before opening the fuel system, connect diesel extractor VAS 5226 and release pressure. - Unscrew bleed valve cap. - Connect Adapter V.A.G 1318/20 with Adapter V.A.G 1318/20-1 and Diesel extractor VAS 5226 to bleed valve Turn valve (on T-piece) clockwise into bleed valve to stop. - Check adapter and hose connection for leaks. - Operate remote control V.A.G 1348/3A until fuel flows (free of air bubbles) from bleed valve.

19 Page 19 / 47 - Turn valve on T-piece - arrow - counter-clockwise until completely open again. - Clamp off hose from suction pump VAS 5226 (e.g. with hose clamps up to 25 mm Ø 3094 ) and pull hose off from Adapter V.A.G 1318/ Remove adapter V.A.G 1318/20 from bleed valve. - Install cover onto bleed valve. Fuel tank, emptying Special tools, testers and auxiliary items required Fuel siphoning unit VAS 5190

20 Page 20 / 47 Polydrive key T10202 Not illustrated: Assembly tool T10118 Work procedure Warning! Fuel supply lines are under pressure! Wear eye protection and protective gloves to avoid injuries and skin contact with fuel. Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection. - Observe safety precautions before performing repair work 20-1, Safety precautions when working on fuel supply system. - Open the fuel tank flap. - Push suction hose - arrow - of fuel extractor VAS 5190 about 170 to 180 cm into fuel filler neck and extract fuel. Note:

21 Page 21 / 47 When no more fuel can be extracted the tank is emptied only enough for the sender flange to be opened without danger. The tank may be removed while containing the remaining fuel. If work must be performed on the fuel pumps or fuel tank senders, proceed as follows: - Cut open carpet from point - A - to point - B - in pre-cut area - arrows -. - Remove nuts from cover. If necessary, unbolt backrest support or support mounting. Repair Manual, Body Interior, Repair Group 72, Rear seats Warning! Fuel supply lines are under pressure! Wear eye protection and protective gloves to avoid injuries and skin contact with fuel. Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

22 Page 22 / 47 - Hold a cloth on connections for fuel supply line and auxiliary heater and pull off hose couplings. Note: Release connection by pressing button on hose coupling. - Disconnect connectors for fuel pump and fuel gauge sender. - Remove locking ring from sensor flange using wrench T Carefully pry out sender flange and raise it slightly. - Insert suction hose of fuel siphoning unit VAS 5190 as deeply as possible in right and then left sides of fuel tank and extract fuel. - For work on left side of fuel tank, proceed as described above. - When breather line is pulled off, hose coupling button often cannot be pressed in. In that case, use assembly tool T arrow -. For additional work on components inside of fuel tank, sensor flanges may remain removed.

23 Page 23 / 47 If fuel tank needed only to be emptied, install sender flanges again. - First check that sender flange seals are properly seated. Note: If seals are swollen with fuel, always replace. - Insert sender flange with locating tab in direction of travel - arrow -. - Tighten left and right locking rings using fuel gauge sender Wrench T10202 to 145 Nm. Fuel delivery unit, fuel gauge sender and suction jet pump, removing and installing Special tools, testers and auxiliary items required

24 Page 24 / 47 Wrench T10202 Requirements The fuel tank must be drained 20-1, Fuel tank, emptying, emptying fuel tank. Fuses and arrows - must be removed from their sockets. Connectors and wires for left and right sender flanges have been removed. Locking rings for left and right sender flanges have been removed. Work procedure - Observe safety precautions before performing repair work 20-1, Safety precautions when working on fuel supply system.

25 Page 25 / 47 - Pull off connectors and - 2 -, as well as hose couplings and under right sender flange. - Remove sender flange with pressure regulator. - Unclip black filler hose - arrow - from fuel delivery unit housing on left and right sides of fuel tank. - Pull fuel supply line off fuel delivery unit - arrow - on left and right sides of fuel tank to suction jet pumps. - Unscrew fuel delivery unit in bottom of fuel tank by turning approx. 90 to left. Note: The fuel delivery unit housing is filled with fuel. Fuel

26 Page 26 / 47 may run out if the housing is tipped or tilted. - Unclip fuel gauge senders on each side of fuel tank and pull them out. - Unclip suction jet pumps from bottom on each side and remove with a slight turn. - Pull out hose ends through left and right sender openings. Fuel tank with attachments, removing and installing Caution! During all repair procedures on the fuel tank, be aware of the following: Route all the various lines (e.g. for fuel, EVAP system, or vacuum) and electrical wiring so that the original routing positions are restored. Make sure that the Ground (GND) (-) strap between the fuel filler tube and body is securely fastened, to prevent electrostatic charging. Ensure sufficient clearance to all moving or hot components.

27 Page 27 / 47 Special tools, testers and auxiliary items required Wrench T10202 Torque wrench (5 to 50 Nm) V.A.G 1331 Torque wrench (40 to 200 Nm) V.A.G 1332 Engine/transmission jack V.A.G 1383/A Fuel siphoning unit VAS 5190 Diesel extractor VAS 5226

28 Page 28 / 47 Not illustrated: Adapter V.A.G 1318/20 Adapter V.A.G 1318/20-1 Requirements The fuel tank must be drained 20-1, Fuel tank, emptying, emptying fuel tank. Fuses and arrows - must be removed from their sockets. Removing - Observe safety precautions before performing repair work 20-1, Safety precautions when working on fuel supply system. First, release fuel pressure as follows: - Thread adapter V.A.G 1318/20-1 onto adapter V.A.G 1318/20.

29 Page 29 / 47 - Turn valve on T-piece - arrow - counter-clockwise until completely open. - Unscrew bleed valve cap. - Screw adapter V.A.G 1318/20 hand tight onto bleeder valve. - Connect hose from diesel extractor VAS 5226 as illustrated. - Turn valve (on T-piece) clockwise into bleed valve to stop. When fuel pressure has been released: - Remove adapter V.A.G 1318/20 from bleed valve. - Install cover onto bleed valve. - Remove mufflers and mountings 26-1, Muffler with mountings. - Remove driveshaft: Repair Manual, Rear Final Drive, Repair Group 39, driveshafts, removing and installing - Remove rear axle: Repair Manual, Suspension, Wheels, Steering, Repair

30 Page 30 / 47 Group 42, Rear axle, servicing - Open fuel flap and remove fuel tank cap. - Pull rubber gasket off filler neck. - Remove securing bolts on filler neck and pull off Ground (GND) wire Remove wheelhousing liner, rear right: Repair Manual, Body Exterior, Repair Group 66, Wheel housing liner, removing and installing - Unbolt cover plate - arrow -.

31 Page 31 / 47 - Unclip fuel tank breather lines at securing clip attached on longitudinal member. - Remove securing bolts for filler pipe and EVAP canister in wheel housing. - Bend filler neck slightly downward and pull off breather line connections to EVAP canister. Note: Release connection by pressing button on hose coupling. - Disconnect 3-pin connector from Evaporative Emission

32 Page 32 / 47 (EVAP) Flap Motor Position Sensor V144 as well as 2-pin connector from Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 N Disconnect Ground (GND) wire clipped to EVAP canister and remove canister. - Separate fuel pump connectors, on left next to fuel tank. - Remove securing straps with covers on left and right below fuel tank. - Support fuel tank using engine and transmission jack V.A.G 1383 A and remove securing strap at center of fuel tank. - Carefully lower fuel tank about 30 cm. Warning! Fuel supply lines are under pressure! Wear eye protection and protective gloves to avoid injuries and skin contact with fuel. Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection. - Reach between fuel tank and vehicle underbody and pull fuel supply and breather lines off sender flange. When pulling off fuel supply line, hold a cloth around fuel supply line. Note: This step eliminates having to cut open the carpeting in the vehicle interior in the vicinity of sender flange cover. - Lower fuel tank. Installing

33 Page 33 / 47 Installation is performed in the reverse order of removal, noting the following: Connections for breather and fuel lines must engage audibly when joined. Make sure ventilation and fuel lines are not kinked when installed. Secure fuel hoses with spring-type clamps. Ensure fuel hoses are seated securely. The Ground (GND) strap at the fuel filler tube must be securely connected to the body. Note: Before fastening the fuel tank, check that the supply and ventilation lines are still clipped onto the fuel tank. Fuel pumps, checking Checking fuel delivery 20-1, Checking delivery rate Checking current draw of fuel pumps current draw of fuel pumps Checking fuel pump non-return valve fuel pump non-return valve 20-1, Checking 20-1, Checking

34 Page 34 / 47 Special tools, testers and auxiliary items required Polydrive key T10202 Pressure gauge V.A.G 1318 Adapter V.A.G 1318/7 Adapter V.A.G 1318/9 Hose V.A.G 1318/13 Pressure gauge adapter V.A.G 1318/17

35 Page 35 / 47 Special tools, testers and auxiliary items required Remote control connection V.A.G 1348/3A Multimeter V.A.G 1715 Spring-type clip pliers VAS 5024A Diesel extractor VAS 5226 Not illustrated: Adapter V.A.G 1318/20

36 Page 36 / 47 Adapter V.A.G 1318/20-1 Hose V.A.G 1318/24 Adapter cable V.A.G 1348/3-3 Measuring container Wiring diagram Checking delivery rate Test conditions Fuses and arrows - must be removed from their sockets. Fuel pump relays and for left and right fuel delivery units must be removed from their sockets. Battery voltage at least 11.5 V

37 Page 37 / 47 Test sequence - Remove fuel filler cap from fuel filler tube. - Connect remote control for VAG 1348 V.A.G 1348/3A with the adapter cable V.A.G 1348/3-3 to connection - arrow - for fuel pump relay for right fuel delivery unit. - Connect positive clamp of of remote control to positive (B+) terminal in engine compartment. - Thread adapter V.A.G 1318/20-1 onto adapter V.A.G 1318/20. - Turn valve (on T-piece) counter-clockwise until completely open. Warning! Fuel supply lines are under pressure! Before opening the fuel system, connect diesel extractor VAS 5226 and release pressure. - Unscrew bleed valve cap.

38 Page 38 / 47 - Connect Adapter V.A.G 1318/20 with Adapter V.A.G 1318/20-1 and Diesel extractor VAS 5226 to bleed valve Turn valve (on T-piece) clockwise into bleed valve to stop. - When the fuel pressure has been released, the fuel system may be opened. Checking delivery quantity of right pump - Pull fuel supply hose off fuel rail. - Hold hose in measuring container with capacity of at least 1000 cm 3. - Empty measuring container before making measurement. - Operate remote control for 15 seconds: At least 3 fuel per 15 seconds must be delivered. Checking delivery quantity of left pump

39 Page 39 / 47 - Connect remote control for VAG 1348 V.A.G 1348/3A with adapter cable V.A.G 1348/3-3 to connection - arrow - for fuel pump relay for left fuel delivery unit. - Empty measuring container before making measurement. - Operate remote control for 15 seconds again. At least 3 fuel per 15 seconds must be delivered. - Also test both fuel delivery units as follows: - Connect Adapter V.A.G 1348/3-3 to fuel pump relay connections for left and right fuel delivery units. - Operate remote control for 10 seconds: At least 800 cm 3 fuel per 10 seconds must be delivered. If the minimum delivery rate is not attained: - Check the fuel lines for possible restrictions (kinks) or blockages. If lines are OK: - Replace the fuel filter: If the delivery rate has been attained but nevertheless you suspect a fuel supply system malfunction (e.g. intermittent failure of fuel supply system): - Check current draw of fuel pumps 20-1, Checking current draw of fuel pumps. Checking current draw of fuel pumps - Check current draw of each fuel pump separately as follows: - Reconnect all disconnected fuel lines.

40 Page 40 / 47 - Connect current clamp of multimeter V.A.G 1715 to the wire of the 4-pin connector contact arrow - from wiring harness to right fuel delivery unit. - Start the engine and run at idle speed. - Measure current draw of fuel pump. Specification: max. 11 amps. If the current draw is exceeded: Warning! Fuel supply lines are under pressure! Before opening the fuel system, connect diesel extractor VAS 5226 and release pressure. - Right fuel pump is faulty. Replace fuel delivery unit 20-1, Fuel delivery unit, fuel gauge sender and suction jet pump, removing and installing. - Repeat test on left fuel delivery unit. If the current draw is exceeded: - Left fuel pump is faulty. Replace fuel delivery unit 20-1, Fuel delivery unit, fuel gauge sender and suction jet pump, removing and installing. Note: If malfunction in fuel system is sporadic, test can also be performed during a road test, but a second person is required. Checking fuel pump non-return valve Conditions Remote control for VAG 1348 V.A.G 1348/3A is still connected.

41 Page 41 / 47 Note: With this check, the fuel supply line connections from the fuel delivery units to the point at which the pressure gauge V.A.G 1318 is connected will be checked for leaks at the same time. Test sequence - Turn valve on T-piece of adapter V.A.G 1318/20 counterclockwise until completely open. - Connect pressure tester V.A.G 1318 to breather valve as shown using adapter V.A.G 1318/20, V.A.G 1318/20-1, V.A.G 1318/9 and diesel extractor VAS Screw valve on T-piece of adapters V.A.G 1318/20 clockwise into bleed valve to stop. - Open shut off tap of pressure tester and operate remote control briefly to bleed air.

42 Page 42 / 47 - Then, close pressure gauge shut-off tap - arrow - (lever perpendicular to direction of flow). - Operate remote control at short intervals, until a pressure of approx. 4 bar has built up. Warning! Danger of spray when opening the shut-off tap diesel extractor VAS 5226 must be connected. - If pressure builds up too high, lower excess pressure by carefully opening the shut-off tap. - Watch pressure drop on gauge. After 10 minutes the pressure must not drop below a 3.0 bar decrease. If the pressure drops: - Check fuel lines and connections to fuel tank for leaks. If no fault is detected in the wiring: Warning! Fuel supply lines are under pressure! Before opening the fuel system, connect diesel extractor VAS 5226 and release pressure. - In addition, wrap a cloth around the connection to catch fuel which runs out. - Remove pressure gauge V.A.G 1318 with adapters. Checking non-return valve of right pump Test conditions Fuel pump relays and for left and right fuel delivery units must be removed from their sockets.

43 Page 43 / 47 Test sequence - Disconnect 4 pin connector from the left flange - Remove locking ring from left sender flange (fuel filter) using fuel tank sender key T Carefully pry up sender flange and raise it slightly. - Disconnect connector next to fuel filter for attaching pressure tester V.A.G Pull fuel supply hose from right fuel delivery unit off fuel filter Let fuel from connecting piece flow back into tank.

44 Page 44 / 47 - Close pressure gauge shut-off tap - arrow - (lever perpendicular to direction of flow). - Connect pressure tester V.A.G 1318 with adapter V.A.G 1318/7, hose adapter V.A.G 1318/13 and adapter V.A.G 1318/17 as shown. Note: Ensure that fuel supply line connection engages audibly when joined. - Attach connectors to the filter housing and flange again. - Connect remote control for VAG 1348 V.A.G 1348/3A with the adapter cable V.A.G 1348/3-3 to connection - arrow - for fuel pump relay for right fuel delivery unit. - Operate remote control at short intervals, until a pressure of approx. 4 bar has built up. - Watch pressure drop on gauge. After 10 minutes the pressure must not drop below a 3.0 bar decrease. If the pressure drops: - Right fuel pump is faulty. Replace fuel delivery unit 20-1, Fuel delivery unit, fuel gauge sender and suction jet pump, removing and installing.

45 Page 45 / 47 To change pressure tester set-up for left fuel pump: - Open lever of pressure tester and let fuel flow back to fuel tank through hose V.A.G 1318/13. Checking non-return valve of left pump - Pull fuel supply hose from left fuel delivery unit off fuel filter If necessary, disconnect the connectors from the flange and filter housing and then attach pressure tester V.A.G Close pressure gauge shut-off tap - arrow - (lever perpendicular to direction of flow).

46 Page 46 / 47 - Connect pressure tester V.A.G 1318 with adapter V.A.G 1318/7, hose adapter V.A.G 1318/13 and adapter V.A.G 1318/24 as shown. Note: Ensure that fuel supply line connection engages audibly when joined. - Connect remote control for VAG 1348 V.A.G 1348/3A with adapter cable V.A.G 1348/3-3 to connection - arrow - for fuel pump relay for left fuel delivery unit. - Operate remote control at short intervals, until a pressure of approx. 4 bar has built up. - Watch pressure drop on gauge. After 10 minutes the pressure must not drop below a 3.0 bar decrease. If the pressure drops: - Left fuel pump is faulty. Replace left fuel delivery unit 20-1, Fuel delivery unit, fuel gauge sender and suction jet pump, removing and installing.

47 Page 47 / 47 - Open lever of pressure tester and let fuel flow back to fuel tank through hose V.A.G 1318/13. - Remove pressure gauge V.A.G 1318 with adapters.

48 Electronic power control (EPC) Page 1 / Electronic power control (EPC) Bracket Connector Black, 6-pin 10 Nm Throttle Position (TP) Sensor G79 with Accelerator Pedal Position Sensor 2 G185 Not adjustable Remove footwell cover to remove sensor

49 Electronic power control (EPC) Page 2 / 2 Functions of EPC system The position of the accelerator pedal is transmitted to the engine control module via two accelerator pedal position senders (adjustable resistances, accommodated in one housing), that are connected to the accelerator pedal. The position of the accelerator pedal (driver controlled) is a main input for the engine control module. Operation of the throttle valve occurs via an electric motor (throttle valve actuator) in the throttle valve control module. This is true across the entire engine speed and engine load spectrum. The throttle valve is operated by the throttle drive according to the instructions of the Engine Control Module (ECM). With the engine at standstill and the ignition switched on, the Engine Control Module (ECM) activates the throttle valve actuator precisely according to the specifications of the Throttle Position (TP) Sensor. This means, if the accelerator pedal is depressed half way, the throttle drive opens the throttle valve to the same degree; i.e. throttle valve is then opened approx. half way. With engine running (under load) the engine control module can open and close the throttle valve independently of the accelerator pedal position sender. This means. the throttle valve can already be completely opened, although the accelerator pedal is only depressed half-way. An advantage of this is that throttle losses at the throttle valve are avoided. Aside from that, it results in clearly better pollutant output and consumption values under certain load conditions. According to torque requirement outputs from the various components (e.g. air conditioning, automatic transmission, ABS/ESP...), the engine control module calculates a throttle valve open angle that is optimal for a respective situation. Observe safety precautions 20-1, Safety precautions when working on fuel supply system. Observe rules for cleanliness cleanliness. 20-1, Rules for

50 Evaporative emissions (EVAP) system (vehicles with engine code BAA and BMX) Page 1 / Evaporative emissions (EVAP) system (vehicles with engine code BAA and BMX) EVAP canister system components, assembly overview 20-3, EVAP canister system, assembly overview Observe safety precautions 20-1, Safety precautions when working on fuel supply system. Observe rules for cleanliness cleanliness. 20-1, Rules for Function Depending upon air pressure and ambient temperature - more or less fuel vapors will form in the fuel tank. The evaporative emissions system prevents these HCemissions from dispersing into the atmosphere. Fuel vapors pass from the highest point in the tank (on the filler neck) through the expansion tank and into the EVAP canister. The activated charcoal in the canister stores these gases like a sponge. When driving with active Lambda regulation (engine warm), the Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 and the Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 N115, are activated by Engine Control Module based on load and speed. The open duration is dependent on the input signals. When purging (recovery of the activated charcoal), the intake manifold vacuum sucks fresh air in through the vent connection of the EVAP canister. The fuel vapors stored amongst the activated charcoal and fresh air are proportionately supplied to be burned. Without electricity (e.g. open circuit) the Evaporative Emission (EVAP) Canister Purge Regulator Valves remain closed. The EVAP canister is not purged. Function description of leak diagnosis The EVAP system (including fuel tank) is equipped with leak diagnosis. The leak diagnosis will detect whether the system is leaking. The diagnosis operates by pressurizing the system and should detect leaks where the damage exceeds 1 mm in

51 Evaporative emissions (EVAP) system (vehicles with engine code BAA and BMX) Page 2 / 5 diameter. During the diagnostic, the Leak Detection Pump (LDP) V144 generates a positive pressure of approx. 30 mbar in the EVAP canister system. The pump will switch off when the pressure is attained. When the pressure falls to below a certain figure, the pump will switch on again. On Board Diagnostic monitors the switch intervals and stores a DTC in DTC memory if the intervals are too short. Note: Hose connections are secured with either springtype or clamp-type clips. Always replace clamp-type clips with spring-type clips. Spring-type clip pliers VAS 5024 A or hose clip pliers V.A.G 1921 are recommended for installing spring-type clips. EVAP canister system, assembly overview Caution! During all repair procedures on the fuel tank, be aware of the following: Make sure that the Ground (GND) (-) strap between the fuel filler tube and body is securely fastened, to prevent electrostatic charging. Route all the various lines (e.g. for fuel, EVAP system, or vacuum) and electrical wiring so that the original routing positions are restored. Ensure sufficient clearance to all moving or hot

52 Evaporative emissions (EVAP) system (vehicles with engine code BAA and BMX) Page 3 / 5 components. Reservoir Right side Gravity valve Fuel filler tube With connection for Ground (GND) strap to body 5 Nm Bracket Vent line To vacuum connection on

53 Evaporative emissions (EVAP) system (vehicles with engine code BAA and BMX) Page 4 / 5 intake manifold Item Ensure seated tightly Leak Detection Pump (LDP) V144 Black connector, 3-pin Connecting hose Between air filter, Leak Detection Pump (LDP) V144 and Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 N115 Ensure seated tightly 5 Nm Air filter housing Clean if soiled Rubber bushing Note installation position Replace if damaged Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 N115 Black connector, 2-pin EVAP canister Component location: in front right wheelhousing 9 Nm Vent line To vacuum connection on intake manifold Item Ensure seated tightly

54 Evaporative emissions (EVAP) system (vehicles with engine code BAA and BMX) Page 5 / 5 Connector Black, 2-pin Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 Note installation position Rubber bracket Note installation position Vent line Ensure seated tightly Pressure retention valve Checking 20-3, Checking pressure retention valve on EVAP canister Checking pressure retention valve on EVAP canister The pressure retention valve is opened via the gravity valve (on expansion tank) for flow in both directions. ( - Arrow 1 - is the side toward the expansion tank). On the other side, flow is possible in one direction only, to the EVAP canister side - arrow 2 -.

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