CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
13.6
Removing and installing fuel system di‐
agnostic pump - V144- (Eos)
Removing:
– Pull off vacuum line -1-, breather line (air outlet) -2- and breath‐
er line (air inlet) -3-.
– Unscrew nuts -arrows-.
– Remove diagnostic pump with bracket and disconnect elec‐
trical connector.
Installing:
Installation is carried out in the reverse order. When installing,
note the following:
♦ Reconnect electrical connector before securing diagnostic
pump with bracket.
♦ The breather line -2- must engage audibly.
Specified torques: ⇒ page 413
13.7
Checking fuel system for leaks
Special tools and workshop equipment required
♦ Fuel system tester (so-called smoke tester) - KLI 9210-
♦ Adapter hose - KLI 9210/55-1-
♦ Vehicle diagnostic tester
♦ Hose clamps to 25 mm - 3094-
The plug-in connectors for fuel, vacuum and breather lines are
colour coded. There is either a coloured dot on the plug-in con‐
nector or the release button is coloured.
Plug-in connector
Colour code on plug-in connec‐
tor
Fuel supply
Fuel return
Breather
black
blue
white, beige
green
Vacuum
Test specification:
•
A leak has been detected by the fuel system diagnostic pump
- V144- .
•
Guided fault finding has been performed with the vehicle di‐
agnostic tester .
416
Rep. gr.20 - Fuel supply system
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
Preparation of fuel system tester - KLI 9210- :
Note
The fuel system tester - KLI 9210- may differ in appearance de‐
pending on the version.
– Check on fuel system tester - KLI 9210- if there is enough fluid
in smoke generator.
– Set valve -D- to “Hold”.
– Open nitrogen bottle -H-.
– Connect test hose -G- to self-test connection -B-.
– Set valve -D- to “Test”.
– Regulate pressure to 10 in. H2O (25 mbar) with pressure re‐
ducer -J-.
– Set valve -D- to “Hold”.
– Now pressure must be maintained for at least 2 minutes.
Check tester if pressure is not maintained.
Checking fuel system for leaks:
– Connect adapter hose - KLI 9210/55-1- to breather line -A-.
(colour marking: white)
– Connect measuring hose -G- from fuel system tester - KLI
9210- to adapter hose - KLI 9210/55-1- .
– Set valve -D- to “Hold”.
13. Activated charcoal filter system (Golf, Eos with engine code CBFA, CCTA, CCTB)
417
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
– Connect vehicle diagnostic tester to vehicle.
– Start engine and run at idling speed.
– On vehicle diagnostic tester , select operating mode Guided
Functions .
– Select guided function “Checking tank ventilation system for
leaks”.
– Initiate test.
– Observe pressure gauge - KLI 9210- while test is running.
•
Fuel system diagnostic pump - V144- must pump up pressure
in fuel system to at least 7 in. H2O (18 mbar).
The minimum pressure was not reached, but the available pres‐
sure does not drop.
⇒ page 418 . If no pressure drop can be detected: Check
⇒ page 422 .
The minimum pressure was not reached and the available pres‐
sure drops immediately:
– Clamp off hose to activated charcoal filter solenoid valve 1 -
N80- using a hose clip -arrow-.
– Repeat check. If the minimum pressure is reached now, renew
activated charcoal filter solenoid valve 1 - N80- .
If the minimum pressure was again not reached and the available
pressure drops immediately:
– Leak in fuel system: Perform “leak detection in fuel system”
⇒ page 420 .
Switch off ignition if the minimum pressure is reached.
The valve in the fuel system diagnostic pump - V144- closes and
the pressure is retained.
– Observe pressure gauge:
If the pressure drops, clamp off hose to activated charcoal filter
solenoid valve 1 - N80- using a hose clip -arrow-.
– If the pressure does not drop again, renew activated charcoal
filter solenoid valve 1 - N80- .
If the pressure still drops, perform “leak detection in fuel system”
⇒ page 420 .
Pressure retention test
418
Rep. gr.20 - Fuel supply system
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
– Set valve -D- to “Test”. Set the available pressure to 10 in. H2O
(25 mbar).
– Observe pressure gauge -C- and flow meter -E-. When the
throughput quantity decreases and the pressure increases to
10 in. H2O (25 mbar), the fuel system is filled.
Note
Depending on the filling level of the fuel tank, this process can
take up to 3 minutes.
– Once pressure has stabilised, set valve -D- to “Hold”.
•
After 5 minutes the pressure must remain at or above 8 in.
H2O (20 mbar).
If the pressure is not held for at least 5 minutes, localise leak as
follows:
– First check activated charcoal filter solenoid valve 1 - N80- for
leaks. To do this, clamp off hose to activated charcoal filter
solenoid valve 1 - N80- using a hose clip -arrow-.
– Repeat pressure test by setting valve -D- again to “Test”.
– Observe pressure gauge and flow meter. When the through‐
put quantity decreases and the pressure increases to 10 in.
H2O (25 mbar), the fuel system is filled.
– Once pressure has stabilised, set valve -D- to “Hold”.
– If the pressure does not drop again, renew activated charcoal
filter solenoid valve 1 - N80- .
If the pressure still drops, perform “leak detection in fuel system”
⇒ page 420 .
After completing work, perform guided function “checking fuel
tank ventilation system for leaks” using vehicle diagnostic tester .
13. Activated charcoal filter system (Golf, Eos with engine code CBFA, CCTA, CCTB)
419
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
13.7.1
Leak detection in fuel system
Test specification:
•
Procedure for “checking fuel system for leaks” has been com‐
pleted ⇒ page 416 .
•
Fuel system tester - KLI 9210- is connected to vehicle via
adapter hose - KLI 9210/55-1- .
– Connect fuel system tester - KLI 9210- to vehicle battery.
– Remove rear right wheel housing liner.
– Clamp off hose between fuel system diagnostic pump - V144-
and air filter -arrow-.
Eos
Golf
420
Rep. gr.20 - Fuel supply system
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
– Set valve -D- to “Test”.
– Observe pressure gauge -C- and flow meter -E-. When the
throughput quantity decreases and the pressure increases to
10 in. H2O (25 mbar), the fuel system is filled.
– Once pressure has stabilised, set valve -D- to “Hold”.
•
After 5 minutes the pressure must remain at or above 8 in.
H2O (20 mbar).
– If the pressure no longer drops, renew fuel system diagnostic
pump - V144- .
If the pressure is not held for at least 5 minutes or does not build
up, localise leak as follows:
– Fill fuel system with smoke, set valve -D- again to “Test” for
this.
– While fuel system is being filled, press button -I- for smoke
generator for approx. one minute.
The fuel system is now pressurised and filled with smoke.
– Check whether smoke escapes from any fuel system line or
hose. Also check fuel tank cap.
Note
♦ Light up the components and hoses with a strong floodlight. In
the floodlight, smoke is more visible.
♦ For leak detection in accessible areas, an ultrasonic detector
or commercially available leak detecting spray may also be
used.
♦ Depending on how long the fault finding takes, it may be nec‐
essary to press the smoke generator button from time to time.
This ensures that sufficient smoke is present in the fuel sys‐
tem.
♦ To inspect flanges for fuel pump and fuel filter, open assembly
opening in vehicle interior.
– Renew leaking hoses or components.
After completing work, perform guided function “checking fuel
tank ventilation system for leaks” using vehicle diagnostic tester .
13.7.2
Schematic overview of activated charcoal filter system
13. Activated charcoal filter system (Golf, Eos with engine code CBFA, CCTA, CCTB)
421
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
1 - Activated charcoal filter
2 - Location of adapter hose -
KLI 9210/55-1-
❑ For leak detection in fuel
system
3 - Activated charcoal filter sol‐
enoid valve 1 - N80-
4 - Breather line
❑ Throttle valve module -
J338-
5 - Solenoid valve
❑ For fuel system diagno‐
sis pump - V144- .
6 - Vacuum line
❑ To intake manifold
7 - Air filter
❑ For fuel system diagno‐
sis pump - V144- .
8 - Fuel system diagnostic
pump - V144-
9 - Fuel
10 - Cap
13.7.3
Checking vacuum supply of fuel system
diagnostic pump - V144-
Special tools and workshop equipment required
♦ Turbocharger tester - V.A.G 1397A-
♦ T-piece - 251 201 346-
♦ Hose ∅ 6mm
422
Rep. gr.20 - Fuel supply system
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
Note
♦ Fitting location of fuel system diagnostic pump - V144- .
♦ Golf: In rear right wheel housing below wheel housing liner.
♦ Eos: Behind rear right wheel.
Golf:
– Remove rear right wheel and wheel housing liner.
– Pull off vacuum line -1- from fuel system diagnostic pump -
V144- .
– Connect turbocharger tester - V.A.G 1397A- with T-piece and
hose ∅ 6mm, between vacuum line -1- and fuel system diag‐
nostic pump - V144- -2-.
Eos:
– Pull off vacuum line -1- from fuel system diagnostic pump -
V144- .
– Connect turbocharger tester - V.A.G 1397A- with T-piece and
hose ∅ 6mm, between vacuum line -1- and fuel system diag‐
nostic pump - V144- -2-.
All vehicles:
– Switch on measuring range I (absolute pressure measure‐
ment).
– Connect vehicle diagnostic tester and start engine.
– On vehicle diagnostic tester , select operating mode Guided
Functions .
– Select guided function “Checking tank ventilation system for
leaks”.
– Initiate test.
– Observe display on turbocharger tester - V.A.G 1397A- while
test is running.
•
Pressure must pulsate and must remain at or below 0.7 bar
(absolute pressure) during test.
– If pressure exceeds 0.7 bar during test, vacuum supply is too
low. Check vacuum line to intake manifold for possible kinks
or blockages.
13. Activated charcoal filter system (Golf, Eos with engine code CBFA, CCTA, CCTB)
423
2024 VW Passat Owner's Manual
VW Passat B7 Service & Repair Manual
VW Passat B6 Service & Repair Manual
