Volkswagen Workshop Service and Repair Manuals

Renewing paper filter on vaporiser Special tools and workshop equipment required

t  Vehicle diagnosis, testing and information system -VAS 5051B-

t  Diagnostic cable -VAS 5051/6A-

t  Vehicle diagnosis and service information system -VAS 5052-

t  Diagnostic system -VAS 5053-

t  Diagnostic cable -VAS 5052/3-

t  Torque wrench -V.A.G 1331-

t  19 mm tool insert -T10455- t  Circlip pliers (commercially available)   WARNING There is a danger from escaping gas. The system is pressurised. Wear suitable protection such as eye protection and protective gloves. Before opening the system place a cloth around the connection. Then release pressure by carefully loosening the connection. Removing: Perform the following procedure:

–  Release latch -1- and remove protective cover -2-. –  Start engine.   Note

Switching -1- to gas mode is briefly displayed in dash panel insert -K-.

–  Connect diagnostic cable.   WARNING It is forbidden to empty Autogas tanks indoors! There is a danger of explosion and injury! Always empty fuel tanks outdoors! –  Switch vehicle diagnosis tester on. –  Select „Guided fault finding“ field on screen. If the display is not as shown in the procedure: read → operating instructions for vehicle diagnosis tester. –  Press > field to confirm. –  Select one after another: t  Brand t  Type t  Model year t  Engine codes –  Confirm vehicle identification

–  Select „01 - Systems capable of self-diagnosis“-arrow- and confirm with >.

–  Select „01 - Engine management system“-arrow- and confirm with >.

–  Select „01 - Functions“-arrow- and confirm with >.

–  Select „Read pressure in gas rail“ function -arrow- and confirm with >. Test starts   Note Read and observe safety information displayed! –  Confirm safety note with > field.

Actual value -arrow- is displayed. –  Undo nut -1- from gas tank valve -N495--2- and pull valve off -in direction of arrow-.   Note

Connector remains connected. Gas tank valve -N495- must close audibly. The reduction of pressure can take several minutes but can also be speeded up by several gas surges.

The gas line is almost pressureless when the pressure indicator -arrow- has fallen. –  Confirm > field. –  The following functions can be selected with fields 1 to 3: t  1 = pressure relief was OK (process is ended) t  2 = pressure relief was not OK (process is repeated) t  3 = ended (process is cancelled) –  Stop engine.

–  Remove bolts -1 and 2-. –  Unscrew nut and bolt -3- and remove bracket for gas filter housing. –  Release gas hose from vaporiser and lay to one side with filter.

–  Release and disconnect connector -2- from gas mode high-pressure valve -N372--1-.   WARNING There is a danger from escaping gas. The system is pressurised. Wear suitable protection such as eye protection and protective gloves. Before opening the system place a cloth around the connection. Then release pressure by carefully loosening the connection.

–  Loosen gas line union -arrow- with banjo bolt -1- on gas inlet of filter housing.

–  Loosen filter housing union -arrow- with gas mode high-pressure valve -N372- and remove filter housing with gas mode high-pressure valve -N372-.

–  Using circlip pliers, remove circlip -arrow- from filter housing.

–  Remove filter housing cover and withdraw filter element upwards. Installing: Perform the following procedure: –  Check seal in filter housing for damage and renew if necessary. –  Insert new paper filter. –  Press filter housing cover into solenoid as far as stop and then secure with circlip.   Note Do not damage seal of filter housing.

–  Attach filter housing with gas mode high-pressure valve -N372- to vaporiser -arrow-. Specified torque: 30 ± 2 Nm   Note t  Ensure that you install gas mode high-pressure valve -N372- in correct installation position.

t  Connector of gas mode high-pressure valve -N372- should be at »approx. 11 o'clock«-A-.

–  Attach gas line -1- with banjo bolt to gas inlet of filter housing. Specified torque for gas line with banjo bolt: 15 Nm.

–  Attach connector -2- to gas mode high-pressure valve -N372--1-. –  Attach gas filter with bracket. –  Fit valve for gas tank -N495- in reverse order.

–  Fit protective cover -2- and engage latch -21-. –  Carry out a gas system test (GAP) once installation is complete → Booklet27.1. –  Read fault memory using vehicle diagnostic tester and correct any faults according to repair guidelines.