Beruflich Dokumente
Kultur Dokumente
Workshop Manual
León 2013 ➤
León ST 2013 ➤
Fuel supply system, petrol engines
Engine ID
CMB CHP CJZA CJZB CJSA CXS CJXA CJXE CYV
A A A A
CYV CZC CZE CWV CHZ CZD CJXH CJSB CJXC
B A A A D A
Edition 02.2017
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.
D3E804FD5C5
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety precautions for working on vehicles with start-stop system. . . . . . . . . . . . . . . . . . . 1
1.3 Safety precautions during road tests in which testing and measuring equipment is used . . 2
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Engine identification number / engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Cleanliness specifications for working on the auxiliary heater and fuel system . . . . . . . . . . 4
4 Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.1 Notes on general repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.2 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.3 Routing and attaching pipes and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Contents i
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
ii Contents
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
00 – Technical data
1 Safety instructions
(ERL003307; Edition 02.2017)
⇒ “1.1 Safety precautions when working on fuel supply system”,
page 1
⇒ “1.2 Safety precautions for working on vehicles with start-stop
system.”, page 1
⇒ “1.3 Safety precautions during road tests in which testing and
measuring equipment is used”, page 2
1. Safety instructions 1
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
1.3 Safety precautions during road tests in which testing and measuring equip‐
ment is used
Risk of injury due to unsecured test and measuring equipment
If a front passenger airbag is triggered during an accident, unse‐
cured test and measuring equipment can become dangerous
projectiles.
– Secure test and measuring equipment with seat belts on the
rear seat.
or
– Have a second person operate test and measuring equipment
on the rear seat.
2 Identification
⇒ “2.1 Engine identification number / engine data”, page 3
Cod CX CZ CZ CW CJ CJ CJ CJ CJ CJ
e SA CA EA VA SA SB XA XC XE XH
Emis EU EU EU EU EU EU EU EU EU EU
sion 5 6 6 3, 6- 6 6 6 6 5
stan EU EU
dard 4, 2
s EU DD
5 K
C lt 1.4 1.4 1.4 1.6 1.8 1.8 2.0 2.0 2.0 2.0
ap r.
ac
ity
En k 90 92 110 81 132 132 206 221 195 213
gi W
ne
ou
tp
ut
RON 95 95 95 95 95 95 95 95 95 95
un‐ un‐ un‐ un‐ un‐ un‐ un‐ un‐ un‐ un‐
lea‐ lea‐ lea‐ lea‐ lea‐ lea‐ lea‐ lea‐ lea‐ lea‐
ded ded ded ded ded ded ded ded ded ded
1) 1)
3 General notes
⇒ “3.1 Cleanliness specifications for working on the auxiliary
heater and fuel system”, page 4
4 Repair notes
⇒ “4.1 Notes on general repairs”, page 5
⇒ “4.2 Contact corrosion”, page 5
⇒ “4.3 Routing and attaching pipes and wiring”, page 5
4. Repair notes 5
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
1.1.1 Assembly overview - fuel tank, vehicles with multi-link rear suspension
4 - Bolt.
❑ Must be renewed if removed
❑ 20 Nm + 90°
5 - Bolt.
❑ Must be renewed if removed
❑ 8 Nm + 90°
6 - Sealing cap
❑ Screw down until it clicks audibly
❑ Fitted on tank flap unit with a securing device
7 - Bolt.
❑ Must be renewed if removed
❑ To secure fuel filler neck
❑ For diverting electrostatic charge
❑ 8 Nm + 90°
8 - Earth connection
❑ For fuel filler neck
❑ For diverting electrostatic charge
9 - Bleeder hose
❑ To activated charcoal filter
❑ Clipped onto fuel tank.
❑ Do not kink.
❑ To remove press release tab on connection element
❑ Connections for fuel lines must engage audibly when joined.
❑ Ensure push-fit couplings are secured properly by pulling.
❑ Opening the quick-release couplings ⇒ page 68
10 - Bleeder hose
❑ To activated charcoal filter
❑ Clipped onto fuel tank.
❑ Do not kink.
❑ To remove press release tab on connection element
❑ Connections for fuel lines must engage audibly when joined.
❑ Ensure push-fit couplings are secured properly by pulling.
❑ Opening the quick-release couplings ⇒ page 68
11 - Fuel tank
❑ Removing and fitting ⇒ page 11
12 - Bolt.
❑ Must be renewed if removed
❑ 20 Nm + 90°
13 - Nut
❑ For heat shield
❑ 2 Nm
14 - Heat shield
❑ For fuel tank
15 - Securing strap
16 - Bolts
❑ Must be renewed if removed
❑ 20 Nm + 90°
1. Fuel tank 7
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
1.1.2 Assembly overview - fuel tank, vehicles with front drive and trailing arm rear
suspension
1 - Sealing cap
❑ Screw down until it
clicks audibly
❑ Fitted on tank flap unit
with a securing device
2 - Earth connection
❑ For fuel filler neck
❑ For diverting electro‐
static charge
3 - Bolt.
❑ Must be renewed if re‐
moved
❑ 8 Nm + 90°
4 - Locking ring
❑ 110 Nm ± 5 Nm
5 - Oil seal
❑ seal
❑ Mount dry
6 - Fuel delivery unit
❑ Assembly overview
⇒ page 52
❑ Removing and fitting
⇒ page 55
❑ With fuel level indicator
sensor - G-
❑ Removing and installing
the fuel gauge sender -
G- ⇒ page 64
❑ With the fuel pump
(pressurisation pump) -
G6-
❑ Check the fuel pump
(pressurisation pump) - G6- ⇒ page 83
❑ Connections on fuel delivery unit
7 - Fuel tank
❑ Removing and fitting ⇒ page 17
8 - Heat shield
❑ For fuel tank
9 - Locking plate
❑ 4 pieces
❑ For heat shield
10 - Securing strap
❑ Ensure proper seating
❑ Mark the direction before removal
11 - Bolt.
❑ Must be renewed if removed
❑ 20 Nm + 90°
8 Rep. gr.20 - Fuel supply system Volkswagen Technical Site: http://vwts.ru http://vwts.info
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
12 - Support bracket
❑ For fuel pump control unit - J538-
❑ Removing and installing fuel pump control unit - J538- ⇒ page 126 .
13 - Fuel supply line
❑ Partly covered by the fuel tank
❑ Do not kink.
❑ To remove press release tab on connection element
❑ Connections for fuel lines must engage audibly when joined.
❑ Ensure push-fit couplings are secured properly by pulling.
❑ Opening the quick-release couplings ⇒ page 68
14 - Bleeder hose
❑ To activated charcoal filter
❑ From activated charcoal filter solenoid valve 1 - N80-
❑ Do not kink.
❑ To remove press release tab on connection element
❑ Connections for fuel lines must engage audibly when joined.
❑ Ensure push-fit couplings are secured properly by pulling.
❑ Opening the quick-release couplings ⇒ page 68
❑ Checking breather ⇒ page 75
❑ Connection schema ⇒ page 74
15 - Bleeder hose
❑ To activated charcoal filter
❑ Clipped onto fuel tank.
❑ Do not kink.
❑ To remove press release tab on connection element
❑ Connections for fuel lines must engage audibly when joined.
❑ Ensure push-fit couplings are secured properly by pulling.
❑ Opening the quick-release couplings ⇒ page 68
❑ Checking breather ⇒ page 75
❑ Connection schema ⇒ page 74
1. Fuel tank 9
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
1 - Breather line
❑ To activated charcoal fil‐
ter
❑ Do not kink.
❑ Partly covered by the
fuel tank
❑ To remove press re‐
lease tab on connection
element
❑ Connect so it engages
audibly
❑ Press in again and then
pull to check that plug-in
connector is correctly
engaged
2 - Breather line
❑ To activated charcoal fil‐
ter
❑ Do not kink.
❑ To remove press re‐
lease tab on connection
element
❑ Connect so it engages
audibly
❑ Press in again and then
pull to check that plug-in
connector is correctly
engaged
3 - Bolts
❑ 20 Nm
4 - Fuel tank
❑ Removing and fitting
⇒ page 11
5 - Securing strap (left-side)
6 - Bolt.
❑ 20 Nm
7 - Nut
❑ For heat shield
❑ 2 Nm
8 - Heat shield
❑ For fuel tank
9 - Securing strap (right-side)
10 - Bolt.
❑ 20 Nm
11 - Fuel line
❑ To engine
❑ Do not kink.
❑ Partly covered by the fuel tank
❑ To remove press release tab on connection element
❑ Connect so it engages audibly
❑ Press in again and then pull to check that plug-in connector is correctly engaged
12 - Fuel pump control unit - J538-
❑ Removing and fitting ⇒ page 126
13 - Bolt.
❑ 8 Nm
14 - Sealing plug
❑ Screw down until it clicks audibly
❑ Fastened with a safety line on the tank flap unit
15 - Bolt.
❑ To secure fuel filler neck
❑ For diverting electrostatic charge
❑ 8 Nm
♦ Wedge - 3409-
1. Fuel tank 11
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
Removal:
– Drain fuel tank ⇒ page 34 .
– Move front seats as far forwards as possible.
– Switch off ignition.
– Remove rear seat bench ⇒ General body repairs, interior;
Rep. gr. 72 ; Rear seats; Removing and installing seat bench/
individual seats .
– Unclip cover -1- of cover flange from the retaining tabs using
the lever - 3409- -arrows-.
Note
Seal off opening of fuel filler neck with a clean plug to prevent dirt
from entering.
1. Fuel tank 13
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
– Pull breather lines -1- and -2- off activated charcoal filter.
Opening the quick-release coupling ⇒ page 68 .
– Unclip breather pipes from bracket -arrow-.
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
1. Fuel tank 15
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
Note
♦ For illustration purposes the fuel tank is shown without the en‐
gine and gearbox jack - VAS 6931- .
♦ The aid of a 2nd mechanic is required to remove the fuel tank.
– Lower fuel tank with engine and gearbox jack - VAS 6931- .
– Lower fuel tank by turning it sideways.
– Observe lines to activated charcoal filter (unclip them, if nec‐
essary).
– Guide filler neck out between rear axle and body.
Installation
Installation is in the reverse sequence of removal. The following
must be taken into account:
– Insert filler neck between rear axle and body.
Note
– Make sure that the filler neck of the fuel tank is correctly in‐
serted into the opening in the body.
– The breather and fuel lines are to be installed without any
kinks.
– After installing fuel tank, check that the supply, return and
breather lines are still clipped onto the fuel tank.
– Position the fuel tank together with retaining strap on under‐
body, using the engine and gearbox jack - VAS 6931- .
– Check correct seat of the exhaust system bracket ⇒ Rep. gr.
26 ; Exhaust pipes / Silencers .
– Note position of securing strap.
– Ensure that line connections are tight.
– Ensure connections are secured properly by pulling.
WARNING
Risk of explosion of fuel tank caused by fuel pump activation.
Risk of severe injuries and burns.
– If a new or completely empty fuel tank has been installed, fill
it immediately with at least 5 litres of fuel.
Specified torques
♦ ⇒ “1.1.1 Assembly overview - fuel tank, vehicles with multi-link
rear suspension”, page 6
♦ ⇒ Rep. gr. 72 ; Rear seats; assembly overview - seat bench /
individual seats (rear) .
♦ ⇒ Rep. gr. 26 ; Exhaust pipes/silencer .
♦ ⇒ Rep. gr. 55 ; Tank flap unit; assembly overview - tank flap
unit.
♦ ⇒ Rep. gr. 66 ; Wheel housing liner; assembly overview - rear
wheel housing liner .
1. Fuel tank 17
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
♦ Wedge - 3409-
Note
Seal off opening of fuel filler neck with a clean plug to prevent dirt
from entering.
1. Fuel tank 19
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
– Pull breather lines -1- and -2- off activated charcoal filter.
Opening the quick-release coupling ⇒ page 68 .
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
1. Fuel tank 21
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
Note
Note
Note
WARNING
Risk of explosion of fuel tank caused by fuel pump activation.
Risk of severe injuries and burns.
– If a new or completely empty fuel tank has been installed, fill
it immediately with at least 5 litres of fuel.
Specified torques
♦ ⇒ “1.1.2 Assembly overview - fuel tank, vehicles with front
drive and trailing arm rear suspension”, page 8
♦ ⇒ General body repairs, interior; Rep. gr. 72 ; Rear seats;
rear seat bench / remove and install individual seats (rear) .
♦ ⇒ 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;
Removing and installing rear axle .
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody
cover .
1. Fuel tank 23
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
♦ Wedge - 3409-
Note
Seal off opening of fuel filler neck with a clean plug to prevent dirt
from entering.
– Pull breather lines -1- and -2- off activated charcoal filter.
Opening the quick-release coupling ⇒ page 68 .
1. Fuel tank 25
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
Note
Note
Note
1. Fuel tank 27
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
WARNING
Risk of explosion of fuel tank caused by fuel pump activation.
Risk of severe injuries and burns.
– If a new or completely empty fuel tank has been installed, fill
it immediately with at least 5 litres of fuel.
Specified torques
♦ ⇒ “1.1.2 Assembly overview - fuel tank, vehicles with front
drive and trailing arm rear suspension”, page 8
♦ ⇒ General body repairs, interior; Rep. gr. 72 ; Rear seats;
rear seat bench / remove and install individual seats (rear) .
♦ ⇒ 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;
Removing and installing rear axle .
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liner; Assembly overview- rear wheel housing liner .
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody
cover .
1. Fuel tank 29
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
Note
Seal off opening of fuel filler neck with a clean plug to prevent dirt
from entering.
1. Fuel tank 31
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
Note
♦ For illustration purposes the fuel tank is shown without the en‐
gine and gearbox jack - VAS 6931- .
♦ The aid of a 2nd mechanic is required to remove the fuel tank.
– The second mechanic must support the fuel tank at the rear
by hand.
– Lower fuel tank with engine and gearbox jack - VAS 6931- .
– Lower fuel tank by turning it sideways.
– Guide filler neck out between rear axle and body.
– The second mechanic must take out the fuel filler neck at the
trailing arm by hand.
Installation
Installation is carried out in the reverse order; note the following:
– The breather and fuel lines are to be installed without any
kinks.
– Make sure that the filler neck of the fuel tank is correctly in‐
serted into the opening in the body.
– Position the fuel tank together with retaining strap on under‐
body, using the engine and gearbox jack - VAS 6931- .
– Note position of securing strap.
– After installing fuel tank, check that the supply, return and
breather lines are still clipped onto the fuel tank.
– Check the proper seat of the bracket for the exhaust system⇒
Rep. gr. 26 ; Exhaust pipes/silencers; Assembly overview -
Silencers .
– Ensure that line connections are tight.
– Ensure connections are secured properly by pulling.
1. Fuel tank 33
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
WARNING
Risk of explosion of fuel tank caused by fuel pump activation.
Risk of severe injuries and burns.
– If a new or completely empty fuel tank has been installed, fill
it immediately with at least 5 litres of fuel.
Specified torques
♦ ⇒ “1.1.2 Assembly overview - fuel tank, vehicles with front
drive and trailing arm rear suspension”, page 8
♦ ⇒ Propshaft and rear final drive; Rep. gr. 39 ; Propshaft; As‐
sembly overview - propshaft
♦ ⇒ General body repairs, interior; Rep. gr. 72 ; Rear seats;
rear seat bench / remove and install individual seats (rear) .
♦ ⇒ 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;
Removing and installing rear axle .
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liner; Assembly overview- rear wheel housing liner .
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody
cover .
Note
1. Fuel tank 35
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
Note
If the fuel extraction unit - VAS 5190 A- is still fitted with the ex‐
traction hose with a solid tip, the extraction hose must be replaced
with the version with a screwed tip.
Note
– Pull off fuel supply line -1-. Opening the quick-release coupling
⇒ page 68 .
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
– Unclip cover -1- of cover flange from the retaining tabs using
the lever - 3409- -arrows-.
Note
The following operation is to make the fuel pump run when the
engine is stopped.
1. Fuel tank 37
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
NOTICE
Risk of irreparable damage to fuel pump if allowed to run dry.
– Never allow fuel pump to run »dry«.
1.3.2 Emptying fuel tank with fuel pump intact, engine code CWVA
Note
If the fuel extraction unit - VAS 5190 A- is still fitted with the ex‐
traction hose with a solid tip, the extraction hose must be replaced
with the version with a screwed tip.
– Pull off fuel supply line -1-. Opening the quick-release coupling
⇒ page 68 .
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
– Connect fuel extractor - VAS 5190 A- with adapter for fuel ex‐
tractor - VAS 5190 /3- to fuel supply line.
– Secure earth wire of fuel extractor to a bare metal part of the
body.
1. Fuel tank 39
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
Note
The following operation is to make the fuel pump run when the
engine is stopped.
NOTICE
Risk of irreparable damage to fuel pump if allowed to run dry.
– Never allow fuel pump to run »dry«.
1. Fuel tank 41
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
– 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- on the lower end of the fuel filler neck in the
fuel tank which must not be damaged by the extraction hose.
Therefore, only push the hose in as far as the tape 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.
Note
Note
1. Fuel tank 43
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
– Separate fuel line -1- using sealing flange. Opening the quick-
release coupling ⇒ page 68 .
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
1.3.5 Emptying fuel tank with fuel tank more than 3/4 full, engine code CWVA
1. Fuel tank 45
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
1. Fuel tank 47
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
1.3.6 Emptying fuel tank with fuel tank less than 3/4 full, vehicles with all-wheel
drive
1. Fuel tank 49
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
1. Fuel tank 51
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
2.1.1 Exploded view - fuel delivery unit/fuel supply sender on vehicles with front-
wheel drive
6 - Electric connector
❑ For fuel system pressurisation pump - G6- and fuel gauge sender - G-
❑ Ensure proper engagement; check if connector is engaged correctly by pulling.
7 - Fuel supply line
❑ To engine
❑ Do not kink.
❑ To remove press release tab on connection element
❑ Connections for fuel lines must engage audibly when joined.
❑ Ensure push-fit couplings are secured properly by pulling.
❑ Opening the quick-release couplings ⇒ page 68
8 - Fuel gauge sender - G-
❑ Checking ⇒ Vehicle diagnostic tester
❑ Removing and fitting ⇒ page 64
2.1.2 Exploded view - fuel delivery unit/fuel supply sender on vehicles with all-
wheel drive
♦ Wrench - T10202-
♦ Wedge - 3409-
Removal:
– Observe the safety measures ⇒ page 1
– Observe rules for cleanliness ⇒ page 4 .
– The fuel tank must not be more than 3/4 full. Therefore, it is
guaranteed that the fuel gauge in the container lies beneath
the fuel delivery unit flange.
– Drain fuel tank ⇒ page 34 .
– Remove rear seat bench ⇒ General body repairs, interior;
Rep. gr. 72 ; Rear seats; Removing and installing seat bench/
individual seats .
– Unclip cover -1- for flange at retaining tabs -arrows-, using re‐
moval wedge - 3409- .
– Separate fuel line -1- using sealing flange. Opening the quick-
release coupling ⇒ page 68 .
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
Note
Installation
Installation is in the reverse sequence of removal. The following
must be taken into account:
Note
– Insert dry seal -1- for fuel delivery unit into opening in fuel tank.
– When inserting fuel delivery unit, ensure that fuel gauge send‐
er is not bent.
– Coat inner side of seal -1- with fuel.
– Press down sealing flange -2- against spring force.
– Move flange to installation position.
– The arrow -3- on the fuel tank must point to marking -2- on
sealing flange -1-.
– The seal must not be crushed or damaged when installing the
flange.
– Push fuel line -1- onto sealing flange until it engages audibly.
WARNING
Risk of explosion of fuel tank caused by fuel pump activation.
Risk of severe injuries and burns.
– If a new or completely empty fuel tank has been installed, fill
it immediately with at least 5 litres of fuel.
Specified torques
♦ ⇒ “2.1 Assembly overview - fuel delivery unit, fuel gauge send‐
er”, page 52
♦ Wedge - 3409-
Removal:
– The fuel tank must not be more than 3/4 full. Therefore, it is
guaranteed that the fuel gauge in the container lies beneath
the fuel delivery unit flange.
– Drain fuel tank ⇒ page 34 .
– Remove rear seat bench ⇒ General body repairs, interior;
Rep. gr. 72 ; Rear seats; Removing and installing seat bench/
individual seats .
– Disconnect earth wire from battery terminal ⇒ Electrical sys‐
tem; Rep. gr. 27 ; Battery, Disconnecting and connecting
battery .
– Unclip cover -1- for flange (right-side) at retainers -arrows- us‐
ing removal wedge - 3409- .
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
– Pull right flange -2- for a short distance out of the opening in
the fuel tank.
– Remove seal -1- from opening in fuel tank.
– Carefully pull out fuel delivery unit -1- with fuel gauge sender
- G- -2- through opening in fuel tank by turning and tilting it as
required.
Note
♦ When removing the fuel delivery unit, ensure that the float arm
of the fuel gauge sender is not bent.
♦ If delivery unit is to be renewed, old delivery unit must be
drained before disposal.
♦ Please observe requirements for disposal.
♦ Check fuel tank for foreign bodies and dirt.
WARNING
Risk of explosion of fuel tank caused by fuel pump activation.
Risk of severe injuries and burns.
– If a new or completely empty fuel tank has been installed, fill
it immediately with at least 5 litres of fuel.
Note
♦ Push on supply line for suction-jet pump and supply line until
it engages audibly.
♦ Insert new 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 with fuel.
♦ Check connectors are secured properly by pulling.
3 Sensors
⇒ “3.1 Removing and installing the fuel gauge sender G ”,
page 64
⇒ “3.2 Removing and installing fuel gauge sender 2 G169 ”, page
65
♦ Wrench - T10202-
Removal:
– Observe the safety measures ⇒ page 1
– Observe rules for cleanliness ⇒ page 4 .
– Switch off ignition.
– Remove rear seat bench ⇒ General body repairs, interior;
Rep. gr. 72 ; Rear seats; Removing and installing seat bench/
individual seats .
3. Sensors 65
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Fuel supply system, petrol engines - Edition 02.2017
Note
3. Sensors 67
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
4 Quick-release couplings
⇒ “4.1 Separating push-on couplings”, page 68
Note
♦ The push-on couplings 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 68 .
♦ Connections for fuel lines must engage audibly when joined.
♦ Ensure push-fit couplings are secured properly by pulling.
Colour assignment
Plug-in connector Colour code on connector
Fuel supply line black
Fuel return Blue
Breather White, beige
Vacuum green
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
Version 1
Push-on coupling with release buttons -arrows- on right and left
Opening
It is necessary to counterhold the separating point for fuel -1- in
the engine compartment.
– Insert lever between heat shield and stop - T10468- -arrow- of
fuel line -2- and counterhold.
4. Quick-release couplings 69
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Fuel supply system, petrol engines - Edition 02.2017
Version 2
Push-fit coupling with pull-release mechanism -arrow-.
Opening
– Push the plug connector -1- in the direction of the arrow-A-.
– Pull the pull-release mechanism -2- in direction of arrow -B-.
– Pull the plug connector -1- in the direction of the arrow -B- off
the fuel line-3-.
Take note of colour assignment during installation ⇒ page 68
Connections for fuel lines must engage audibly when joined.
– Ensure push-fit couplings are secured properly by pulling.
Version 3
Push-fit coupling with front button -arrow-
Opening
– Press release button -arrow- and pull push-on connectors off.
Take note of colour assignment during installation ⇒ page 68 .
Connections for fuel lines must engage audibly when joined.
– Ensure push-fit couplings are secured properly by pulling.
Version 4
Push-fit coupling with release button -arrows- on right and left
Opening
– Press push-on coupling in -direction of arrow A-.
– Press release buttons -arrows- and pull push-on coupling off.
Take note of colour assignment during installation ⇒ page 68 .
Connections for fuel lines must engage audibly when joined.
– Ensure push-fit couplings are secured properly by pulling.
Version 5
Push-fit connector with release buttons -arrows- on right and left
Opening
– Press release buttons -arrows- and pull push-on coupling off.
Take note of colour assignment during installation ⇒ page 68 .
Connections for fuel lines must engage audibly when joined.
– Ensure push-fit couplings are secured properly by pulling.
Version 6
Push-fit connector with release buttons -arrows- on right and left
Opening
– Press the lug connector -1- in the direction of the -arrow- and
keep it pressed.
– Press release buttons -arrows- and pull push-on coupling off.
Take note of colour assignment during installation ⇒ page 68 .
Connections for fuel lines must engage audibly when joined.
– Ensure push-fit couplings are secured properly by pulling.
Version 7
Plug-in connector -1- with release buttons -2- on right and left:
Opening
– Press the plug connector -1- in the direction of the arrow -A-
and keep it pressed.
– Press the release button -2- in the direction of the arrow -B-
and pull off the plug connector -1-.
Take note of colour assignment during installation ⇒ page 68 .
Connections for fuel lines must engage audibly when joined.
– Ensure push-fit couplings are secured properly by pulling.
4. Quick-release couplings 71
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5 Fuel filter
Pressure limiting valve and fuel filter are integrated in fuel delivery
unit and cannot be renewed individually ⇒ page 55 .
1 - Bleeder hose
❑ to activated charcoal fil‐
ter solenoid valve 1 -
N80-
❑ Clipped onto fuel tank.
❑ Checking breather
⇒ page 75
❑ Connection schema
⇒ page 74
❑ To remove press re‐
lease tab on connection
element
❑ Connections for fuel
lines must engage audi‐
bly when joined.
❑ Ensure push-fit cou‐
plings are secured prop‐
erly by pulling.
❑ Opening the quick-re‐
lease couplings
⇒ page 68
2 - Bolt.
❑ 20 Nm
3 - Active carbon filter
❑ Fitting location: At rear
right beneath rear shelf
❑ Removing and fitting
⇒ page 74
❑ Checking breather
⇒ page 75
4 - Bleeder hose
❑ To fuel tank
❑ To remove press re‐
lease tab on connection
element
❑ Connections for fuel lines must engage audibly when joined.
❑ Ensure push-fit couplings are secured properly by pulling.
❑ Opening the quick-release couplings ⇒ page 68
❑ Checking breather ⇒ page 75
❑ Connection schema ⇒ page 74
Note
Specified torques
♦ ⇒ “6.1 Exploded view - activated charcoal filter system”, page
73
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liners; Assembly overview- rear wheel housing liner .
♦ ⇒ Suspension, axles, steering; Rep. gr. 44 ; rims and tyres;
tyre change
7 Accelerator control
⇒ “7.1 Assembly overview - accelerator module”, page 81
⇒ “7.2 Removing and installing accelerator module GX2 ”,
page 82
1 - Bolt.
❑ 6 Nm
2 - Electric connector
❑ Make sure it is engaged
properly; pull to check
that plug-in connector is
correctly engaged
3 - Accelerator pedal module -
GX2-
❑ Includes the following
parts:
Accelerator position
sender - G79-
Accelerator position
sender 2 - G185-
❑ Removing and fitting
⇒ page 82
7. Accelerator control 81
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8 Fuel pump
⇒ “8.1 Checking fuel system pressurisation pump G6 ”,
page 83
⇒ “8.2 Removing and installing fuel pump control unit J538 ”, page
126
⇒ “8.3 Removing and installing suction-jet pump”, page 129
8. Fuel pump 83
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
Note
Note
8. Fuel pump 85
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
– Check voltage supply between contacts -3- and -4- using mul‐
timeter ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
– Use auxiliary measuring set - V.A.G 1594C- to do this.
– Switch ignition on.
• Specification: approx. battery voltage
If specification is not obtained:
– Locate and rectify open circuit using current flow diagram
⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐
cations.
If no fault is found:
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
– Check electrical wiring between flange and fuel pump for con‐
tinuity using an ohmmeter.
– Check contacts for damage.
If there is cable integrity:
– Fuel pump is defective, renew fuel delivery unit ⇒ page 55 .
8. Fuel pump 87
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Fuel supply system, petrol engines - Edition 02.2017
Note
Note
– Unclip cover -1- for flange at retaining tabs -arrows-, using re‐
moval wedge - 3409- .
– Unclip cover -1- for flange (right-side) at retainers -arrows- us‐
ing removal wedge - 3409- .
8. Fuel pump 89
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Fuel supply system, petrol engines - Edition 02.2017
If no fault is found:
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
Prerequisites:
• Voltage supply okay ⇒ page 83 .
– Observe the safety measures ⇒ page 1
– Observe rules for cleanliness ⇒ page 4 .
– Pull off supply line -1-. Opening the quick-release coupling
⇒ page 68 .
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
8. Fuel pump 91
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Fuel supply system, petrol engines - Edition 02.2017
– Make sure that the radiator shut-off tap -C- is connected to the
pressure gauge -1-.
– The cut-off valves -A- and -B- are open on the pressure gauge
-1-.
– Connect vehicle diagnostic tester .
– Select final control diagnosis for fuel pump in vehicle self-di‐
agnosis program.
Note
– Unclip cover -1- for flange at retaining tabs -arrows-, using re‐
moval wedge - 3409- .
– Pull fuel line -1- out of sealing flange. Opening the quick-re‐
lease coupling ⇒ page 68 .
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
8. Fuel pump 93
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Fuel supply system, petrol engines - Edition 02.2017
– Make sure that the radiator shut-off tap -C- is connected to the
pressure gauge -1-.
– The cut-off valves -A- and -B- are open on the pressure gauge
-1-.
– Repeat the diagnosis of the regulating elements to build up the
fuel pressure.
If result matches specification:
– Check to ensure that there are no crushing points (kinks) or
blockages in the fuel pipes.
– Check fuel line for leaks and damage.
If specification is not obtained:
– Remove fuel delivery unit ⇒ page 55 and check for contami‐
nation.
– Check that all hoses are connected.
– Check to ensure that there are no crushing points (kinks) or
blockages in the fuel pipes.
– Check fuel lines for leaks and damage.
If no fault is found:
– Fuel pump is defective, renew fuel delivery unit ⇒ page 55 .
Prerequisites:
• Voltage supply okay ⇒ page 83 .
– Observe the safety measures ⇒ page 1
– Observe rules for cleanliness ⇒ page 4 .
– Pull off supply line -1-. Opening the quick-release coupling
⇒ page 68 .
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
8. Fuel pump 95
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
– Make sure that the radiator shut-off tap -C- is connected to the
pressure gauge -1-.
– The cut-off valves -A- and -B- are open on the pressure gauge
-1-.
– Connect vehicle diagnostic tester .
– Select final control diagnosis for fuel pump in vehicle self-di‐
agnosis program.
Note
– Unclip cover -1- for flange at retaining tabs -arrows-, using re‐
moval wedge - 3409- .
– Pull fuel line -1- out of sealing flange. Opening the quick-re‐
lease coupling ⇒ page 68 .
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
8. Fuel pump 97
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
– Make sure that the radiator shut-off tap -C- is connected to the
pressure gauge -1-.
– Shut-off valves -A- and -B- on pressure tester -1- are open.
– Repeat the diagnosis of the regulating elements to build up the
fuel pressure.
If result matches specification:
– Check to ensure that there are no crushing points (kinks) or
blockages in the fuel pipes.
– Check fuel line for leaks and damage.
If specification is not obtained:
– Remove fuel delivery unit ⇒ page 55 and check for contami‐
nation.
– Check that all hoses are connected.
– Check to ensure that there are no crushing points (kinks) or
blockages in the fuel pipes.
– Check fuel lines for leaks and damage.
If no fault is found:
– Fuel pump is defective, renew fuel delivery unit ⇒ page 55 .
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
8. Fuel pump 99
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Fuel supply system, petrol engines - Edition 02.2017
– Connect fuel line from fuel tank to shut-off tap -B- of pressure
tester - VAS 6550/2- by means of hose - VAS 6550- .
– Connect fuel line leading to engine -1- to shut-off tap -A- of
pressure tester - VAS 6550/1- by means of hose - VAS 6550- .
Checking process:
– Connect vehicle diagnostic tester .
– Select final control diagnosis for fuel pump in vehicle self-di‐
agnosis program.
Note
If no fault is found:
– Make sure that the radiator shut-off tap -C- is connected to the
pressure gauge -1-.
– The cut-off valves -A- and -B- are open on the pressure gauge
-1-.
– Actuate fuel pump with final control diagnosis to build up fuel
pressure.
– After pressure has built up, close shut-off tap -A- of pressure
tester immediately. The lever must point horizontally in the
flow direction.
If the pressure drops again (leak on fuel tank side):
Check the residual pressure in the fuel delivery unit. Proceed as
follows ⇒ page 101 :
If the pressure does not drop now (leak on engine side):
Note
Search for the leak on the engine side. Check the retention pres‐
sure again. Now close cut-off valve -B- to check whether there is
in fact a leak on the engine side.
– Unclip cover -1- for flange at retaining tabs -arrows-, using re‐
moval wedge - 3409- .
– Pull fuel line -1- out of sealing flange. Opening the quick-re‐
lease coupling ⇒ page 68 .
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
– Make sure that the radiator shut-off tap -C- is connected to the
pressure gauge -1-.
– The cut-off valves -A- and -B- are open on the pressure gauge
-1-.
– Actuate fuel pump with final control diagnosis to build up fuel
pressure.
– After pressure has been built up, immediately close the shut-
off valve -B- on the pressure gauge. The lever must point
horizontally in the flow direction.
– Repeat holding pressure check ⇒ page 100 .
If the pressure does not drop any more:
– Test fuel line for tightness.
If the pressure drops again:
– Remove fuel delivery unit -1- ⇒ page 55 .
– Check that all hose connections are connected.
– Check fuel lines for leaks and damage.
If no fault is found:
– If the pressure retention valve in the fuel delivery unit is de‐
fective: Renew the fuel delivery unit ⇒ page 55 .
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
– Connect fuel line from fuel tank to shut-off tap -B- of pressure
tester - VAS 6550/2- by means of hose - VAS 6550- .
– Connect fuel line leading to engine -1- to shut-off tap -A- of
pressure tester - VAS 6550/1- by means of hose - VAS 6550- .
Checking process:
– Connect vehicle diagnostic tester .
– Select final control diagnosis for fuel pump in vehicle self-di‐
agnosis program.
Note
If no fault is found:
– Make sure that the radiator shut-off tap -C- is connected to the
pressure gauge -1-.
– Shut-off valves -A- and -B- on pressure tester -1- are open.
– Actuate fuel pump with final control diagnosis to build up fuel
pressure.
– After pressure has built up, close shut-off tap -A- of pressure
tester immediately. The lever must point horizontally in the
flow direction.
If the pressure drops again (leak on fuel tank side):
Check the residual pressure in the fuel delivery unit. Proceed as
follows ⇒ page 101 :
If the pressure does not drop now (leak on engine side):
Note
Search for the leak on the engine side. Check the retention pres‐
sure again. Now close cut-off valve -B- to check whether there is
in fact a leak on the engine side.
– Unclip cover -1- for flange at retaining tabs -arrows-, using re‐
moval wedge - 3409- .
– Pull fuel line -1- out of sealing flange. Opening the quick-re‐
lease coupling ⇒ page 68 .
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
– Make sure that the radiator shut-off tap -C- is connected to the
pressure gauge -1-.
– The cut-off valves -A- and -B- are open on the pressure gauge
-1-.
– Actuate fuel pump with final control diagnosis to build up fuel
pressure.
– After pressure has been built up, immediately close the shut-
off valve -B- on the pressure gauge. The lever must point
horizontally in the flow direction.
– Repeat holding pressure check ⇒ page 105 .
If the pressure does not drop any more:
– Test fuel line for tightness.
If the pressure drops again:
– Remove fuel delivery unit -1- ⇒ page 55 .
– Check that all hose connections are connected.
– Check fuel lines for leaks and damage.
If no fault is found:
– If the pressure retention valve in the fuel delivery unit is de‐
fective: Renew the fuel delivery unit ⇒ page 55 .
Note
The fuel deliver rate will initially be checked in the engine com‐
partment using the guided function “Checking fuel delivery rate,
quick test”. If the minimum delivery rate is not achieved, a second
measurement must be carried out on the flange of the fuel supply
unit.
Note
– Unclip cover -1- for flange at retaining tabs -arrows-, using re‐
moval wedge - 3409- .
Note
The following operation is to make the fuel pump run when the
engine is stopped.
– Pull fuel line -1- out of sealing flange. Opening the quick-re‐
lease coupling ⇒ page 68 .
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
– Make sure that the radiator shut-off tap -C- is connected to the
pressure gauge -1-.
– The cut-off valves -A- and -B- are open on the pressure gauge
-1-.
– Operate the remote control - V.A.G 1348/3A- .
Note
Note
The fuel deliver rate will initially be checked in the engine com‐
partment using the guided function “Checking fuel delivery rate,
quick test”. If the minimum delivery rate is not achieved, a second
measurement must be carried out on the flange of the fuel supply
unit.
Note
– Unclip cover -1- for flange at retaining tabs -arrows-, using re‐
moval wedge - 3409- .
Note
The following operation is to make the fuel pump run when the
engine is stopped.
– Pull fuel line -1- out of sealing flange. Opening the quick-re‐
lease coupling ⇒ page 68 .
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
– Make sure that the radiator shut-off tap -C- is connected to the
pressure gauge -1-.
– Shut-off valves -A- and -B- on pressure tester -1- are open.
– Operate the remote control - V.A.G 1348/3A- .
Note
Note
The fuel deliver rate will initially be checked in the engine com‐
partment using the guided function “Checking fuel delivery rate,
quick test”. If the minimum delivery rate is not achieved, a second
measurement must be carried out on the flange of the fuel supply
unit.
Note
– Unclip cover -1- for flange at retaining tabs -arrows-, using re‐
moval wedge - 3409- .
Note
The following operation is to make the fuel pump run when the
engine is stopped.
– Pull fuel line -3- off flange. Opening the quick-release coupling
⇒ page 68 .
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
– Make sure that the radiator shut-off tap -C- is connected to the
pressure gauge -1-.
– Shut-off valves -A- and -B- on pressure tester -1- are open.
– Operate the remote control - V.A.G 1348/3A- .
Note
♦ Wedge - 3409-
Procedure:
Removal:
– Move front seats all the way forwards.
– Switch off ignition.
– Remove rear seat bench ⇒ General body repairs, interior;
Rep. gr. 72 ; Rear seats; Removing and installing seat bench/
individual seats .
– Unclip cover -1- for flange at retaining tabs -arrows-, using re‐
moval wedge - 3409- .
– Press up tab -2- -arrow A-; to do so, reach between floor panel
and fuel tank with your finger.
– At the same time carefully pull the fuel pump control unit -1-
on its wiring harness -3- in -direction of arrow B- out of its
holder.
– 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- .
Installation
Installation is in the reverse sequence of removal. The following
must be taken into account:
Location ⇒ “1.1 Assembly overview - fuel tank”, page 6
– Connect wiring harness to fuel pump control unit - J538- .
– Pull on the connections to check if they have been connected
correctly.
– Insert fuel pump control unit - J538- into mounting bracket on
fuel tank and push it in until it audibly engages.
– Pull fuel pump control unit - J538- back in the opposite direc‐
tion to check it is properly secured.
Note