volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

Assembly overview - fuel system > < System layout: vehicles with 0.5 bar low-pressure fuel system
System layout: vehicles with 6.0 bar low-pressure fuel system
System layout: vehicles with 6.0 bar low-pressure fuel system
  WARNING
t  Always read rules for cleanliness and instructions for working on fuel system → Chapter.
t  Always follow these rules for cleanliness and instructions before starting work and while working on the fuel system.
t  If components of the fuel system between tank and high-pressure fuel pump are removed or renewed, the fuel system must be filled to be bled . (It is important not to allow the high-pressure pump to run while still empty.)
To prevent the high-pressure fuel pump from running while it is empty and to ensure that the engine starts quickly after parts have been renewed, it is important to observe the following:
t  If fuel system components between fuel tank and fuel high-pressure pump are removed or renewed;
t  If a fuel system pressurisation pump - G 6 -, fuel line or fuel filter is removed or renewed.
t  If the fuel high-pressure pump is removed or replaced;
–  Connect vehicle diagnosis tester.
–  Perform the function „Fuel pump activation (Filling/bleeding fuel system)“ in „Guided functions“.
   
1 - Fuel tank
q   With fuel system pressurisation pump -G6-.
2 - Fuel filter
q   Assembly overview - fuel filter → Chapter.
q   Removing and installing fuel filter → Chapter.
3 - High-pressure fuel pump
q   After renewing, a first fuel filling „must“ be performed (never allow pump to run while dry).
q   Removing and installing → Chapter.
4 - Fuel metering valve -N290-
q   Do not open.
5 - Fuel pressure sender -G247-
q   Removing and installing → Chapter.
6 - High-pressure accumulator
7 - Fuel pressure regulating valve -N276-
q   Renew.
q   Check → Chapter.
q   Removing and installing → Chapter.
q   80 Nm
8 - Pressure retention valve with fuel return lines
q   The fuel return lines must not be dismantled. They can only be renewed together with the pressure retention valve as one unit.
q   The pressure retention valve maintains a residual pressure of approx. 1 bar in the return lines.
q   This residual pressure is required for the control function of the injectors.
q   The pressure retention valve may only be renewed completely together with the fuel return lines.
q   The pressure retention valve is installed in the fuel return lines just before the metal return line.
q   After replacement, engine must be run at idling speed for approx. 2 minutes to bleed fuel system.
q   Check pressure retention valve → Chapter.
9 - Injectors
q   Injector for No. 1 cylinder -N30-
q   Injector for No. 2 cylinder -N31-
q   Injector for No. 3 cylinder -N32-
q   Injector for No. 4 cylinder -N33-
q   Removing and installing → Chapter.

   

Assembly overview - fuel system > < System layout: vehicles with 0.5 bar low-pressure fuel system