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Fuel supply system - Diesel engines

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CAY CAY CFH CFH CLC CUU CUU CUU CUU

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Service Department. Technical Information

 Service
List of Workshop Manual Repair Groups

Repair Group
00 - Technical data
20 - Fuel supply system

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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.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2019 Volkswagen AG, Wolfsburg D4B8055F1A7

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . .[Link]. ..V. . . .[Link]. A. G. [Link].s.n . . . . . . . . . . 1

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1 Safety information . . . . . . . . . . . . . . . . . .e.d b. y. . . . . . . . . . . . . . . . . . . . . . . . . . .[Link].n. . . . . .
. 1
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1.1 Safety regulations for working on fuel supply ut
ho . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ee. o.r . . .
. 1
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1.2 Safety measures when working on vehicles ss with a start/stop system . . . . . . . . . . . . . c. . . 1

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1.3 Safety precautions when working on the SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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1.4 Safety precautions when using testers and measuring instruments during a road test . . . . 2

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1.5 Safety precautions when working on exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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2.1 Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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3 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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3.1 Rules for cleanliness when working on auxiliary/supplementary heater and fuel system . . 7
4 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1 Routing and attachment of lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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4.2 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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1 Procedure should vehicle be misfueled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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1.1 Procedure should vehicle be misfueled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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2 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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2.1 Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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2.2 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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2.3 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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3 Fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
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3.1 Assembly overview - fuel delivery unit/fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . 40
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3.2 Removing and installing fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . 43
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3.3 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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4 Plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.1 Separating plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.1 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.2 Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.3 Removing and installing upper part of fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.4 Checking fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.5 Removing and renewing fuel hoses in engine compartment, fuel filter with 3 connections
........................................................................ 67
6 Accelerator pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6.1 Assembly overview - accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6.2 Removing and installing accelerator module with accelerator position sender G79 / G185
........................................................................ 69
7 Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7.1 Checking fuel system pressurisation pump G6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7.2 Supplementary fuel pump V393 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Contents i
 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

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ii Contents
 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

00 – Technical data
1 Safety information
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⇒ “1.1 Safety regulations for working on fuel supply”, pageor 1
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⇒ “1.2 Safety measures when working on vehicles with ss a start/
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⇒ “1.3 Safety precautions when working on the SCR system”,

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⇒ “1.5 Safety precautions when working on exhaust system”,
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1.1 Safety regulations for working on fuel supply

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Risk of injury from highly pressurised fuel.
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The fuel system is pressurised. Injury from fuel spray possible.

Before opening the fuel system:

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– Wear protective goggles.

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– Wear protective gloves.

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– To release pressure, wrap a clean cloth around the connection

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Danger of fire caused by escaping fuel Prote
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When the battery is connected and the driver door opens, the door
contact switch activates the fuel pump. Escaping fuel can ignite
and cause a fire.
– Disconnect voltage supply to fuel pump before opening the
fuel system.

1.2 Safety measures when working on vehicles with a start/stop system

Risk of injury due to unexpected motor start
If the vehicle's start/stop system is activated, the engine could
start unexpectedly. A message in the dash panel insert indicates
whether the start/stop system is activated.
– Deactivate start/stop system by switching off the ignition.

1.3 Safety precautions when working on the SCR system

Risk of injury due to reducing agent
The reducing agent may cause eye and skin irritations as well as
injuries to the respiratory system and poisoning.

1. Safety information 1
 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

– Wear protective goggles.

– Wear protective gloves.
– Always wear protective clothes.
– Make sure that a sufficient amount of fresh air is supplied. In
closed areas, switch on the exhaust gas extractor system.

Risk of damage caused by reducing agent

If reducing agent gets onto trim panels and body components, the
reducing agent may solidify after a while and thus damage the
surface.
– Make sure that no reducing agent gets onto the trim panels or
body components.
– If any reducing agent does get onto surfaces, remove it im‐
mediately using water and a cloth.
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1.4 Safety precautions when using testers and measuring instruments during ut or
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When the front passenger airbag is triggered in an accident, in‐
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– Secure testing and measuring instruments on the rear seat.
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– Have a second person operate the test and measuring equip‐

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1.5 Safety precautions when working on exhaust system

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Risk of poisoning due to chemical substances

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Exhaust gas temperature senders may contain chemical sub‐

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– Never open an exhaust gas temperature sender by cutting,
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Risk of injury due to hot condensate and particles in the exhaust

system.
The exhaust system could contain hot condensate and/or parti‐
cles. There is a risk of injury to the eyes, skin and respiratory
system, as well as poisoning.
– Always wear protective gloves and eye protection when cut‐
ting the exhaust system.
– When cutting, use an extraction system or otherwise ensure
sufficient ventilation.

2 Rep. gr.00 - Technical data

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

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1. Safety information 3
 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

2 Identification
⇒ “2.1 Engine number/engine data”, page 4

2.1 Engine number/engine data

The engine number (engine code and serial number) can be
found at the front on the joint between engine and gearbox --.
Additionally there is a sticker with engine code on the upper tooth‐
ed belt guard.
The engine codes have four characters.
The first 3 characters stand for the engine's cubic capacity and
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Codes CAYD CAYE

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Manufactured 08.10 ► 08.10 ►
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Exhaust emissions fulfil EU3 standard EU5 standard
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Displacement l 1.6 1.6

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Power kW at rpm 75/4400 55/
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Torque Nm at rpm 250/ 225/
1500 to 2500 1500-2250

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Bore Diameter, mm 79.5 79.5
Stroke mm 80.5 80.5
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Compression ratio 16.5 16.5

Valves per cylinder 4 4

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Fuel: acc. to DIN EN 590 DIN EN 590

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Firing order 1-3-4-2 1-3-4-2
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Exhaust gas recirculation yes yes

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Catalytic converter yes yes

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Particulate filter yes yes

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Charging yes yes
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Codes CFHC CFHF CLCA

Manufactured 08.10► 04.10► 08.10►
Exhaust emissions fulfil EU5 plus EU5 plus EU4 standard
Displacement l 2.0 2.0 2.0
Power kW at rpm 103/4200 81/ 81/4200
2750 to 4200
Torque Nm at rpm 320/ 280/ 250/
1750 to 2500 1750 to 2500 1500 to 2500
Bore Diameter, mm 81.0 81.0 81.0
Stroke mm 95.5 95.5 95.5
Compression ratio 16.0 16.0 16.0
Valves per cylinder 4 4 4
Fuel: acc. to DIN EN 590 DIN EN 590 DIN EN 590
Firing order 1-3-4-2 1-3-4-2 1-3-4-2
Exhaust gas recirculation yes yes yes

4 Rep. gr.00 - Technical data

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

Codes CFHC CFHF CLCA

Catalytic converter yes yes yes
Particulate filter yes yes No
Charging yes yes yes
Charge air cooling yes yes yes

Codes CUUB CUUC CUUD CUUE CUUF

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Displace‐ s au l 2.0 2.0 2.0 r ac 2.0 2.0
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Power 110/ 55/ 75/ kW at rpm
90/ 55/

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3500-4000 3500-4000 2900-4000 2900-4500 2400-4500

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Torque Nm at rpm 340/ 200/ 340/ 340/ 225/
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1750-3000 1750-3000 1750-3000 1750-3000 1750-3000

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Bore Diameter, mm 81.0 81.0 81.0 81.0 81.0
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Stroke mm 95.5 95.5 95.5 95.5 95.5
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Compression ratio 16.2 16.2 16.2 16.2 16.2
Valves per cylinder 4 4 4 4 4

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RON Diesel EN Diesel EN Diesel EN Diesel EN Diesel EN
590 590 590 590 590
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Injection system Bosch CR Bosch CR Bosch CR Bosch CR Bosch CR

CRI2-20 CRI2-20 CRI2-20 CRI2-20 CRI2-20

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Firing or‐ 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2

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Exhaust gas recirculation yes yes yes yes yes
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Catalytic converter yes yes yes yes yes
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Particulate filter yes yes yes yes yes

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Charging Turbocharg‐ Turbocharg‐ Turbo‐ Turbocharg‐ Turbocharg‐

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Camshaft timing adjustment yes yes yes yes gh
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Codes DFSB DFSC DFSD DFSE DFSF

Exhaust emission standard EU 6 plus EU 6 plus EU 6 plus EU 6 plus EU 6 plus
Displace‐ l 2.0 2.0 2.0 2.0 2.0
ment
Power kW at rpm 110/ 55/ 75/ 90/ 55/
3500-4000 2400-4500 2900-4000 2900-4500 2400-4500
Torque Nm at rpm 340/ 200/ 250/ 300/ 225/
1750-3000 1100-2600 1300-2800 1500-2800 1200-2300
Bore Diameter, mm 81.0 81.0 81.0 81.0 81.0
Stroke mm 95.5 95.5 95.5 95.5 95.5
Compression ratio 16.2 16.2 16.2 16.2 16.2
RON Diesel EN Diesel EN Diesel EN Diesel EN Diesel EN
590 590 590 590 590
Injection system Bosch CR Bosch CR Bosch CR Bosch CR Bosch CR
CRI2-20 CRI2-20 CRI2-20 CRI2-20 CRI2-20
Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2

2. Identification 5
 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

Codes DFSB DFSC DFSD DFSE DFSF

Charging Turbocharg‐ Turbocharg‐ Turbocharg‐ Turbocharg‐ Turbocharg‐
er er er er er
Camshaft timing adjustment No No No No No
Charge air yes yes yes yes yes
cooling
Particulate filter yes yes yes yes yes
Valves per cylinder 4 4 4 4 4

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6 Rep. gr.00 - Technical data

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

3 General information
⇒ “3.1 Rules for cleanliness when working on auxiliary/supple‐
mentary heater and fuel system”, page 7

3.1 Rules for cleanliness AG. Volkswagewhen

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♦ Thoroughly clean all joints and surrounding areas before dis‐

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♦ Place removed parts on a clean surface and cover them over.
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Use lint-free cloths only.
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♦ Carefully cover opened components or seal them if repairs
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cannot be carried out immediately.
♦ Install only clean parts; do not remove new parts from pack‐
aging until immediately before installing. Do not use parts that

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have been kept unpackaged (for example in toolboxes).
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♦ If system is open, do not work with compressed air. Do not

move vehicle unless absolutely necessary.

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♦ Also ensure that no diesel fuel comes into contact with the
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immediately. Renew fuel hoses damaged by fuel.
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♦ Protect disconnected electrical connectors from dirt and water,

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and reconnect them only when dry.

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3. General information 7
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Fuel supply system
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4 Repair instructions

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⇒ “4.2 General repair instructions”, page 8
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4.1 Routing and attachment of lines
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Risk of damage to lines
Lines may become damaged by moving or hot components.

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– Route lines in their original positions.
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– Ensure there is sufficient clearance to moving or hot compo‐

nents.

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♦ Mark fuel lines, vacuum lines, pipes/hoses for activated char‐

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coal filter system and electrical wiring etc. before removal so

um
for

en
they can be re-installed in the original positions and correctly
ng

t.
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connected. Where necessary, make sketches or take photo‐ . Cop py
graphs.
ht rig
rig ht
py by
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4.2 General repair instructions
by lksw
cted agen
Prote AG.

Before starting work on the fuel supply system, the following steps
must be performed:
♦ Before starting work, the extraction hose of a switched-on ex‐
haust gas extraction system must be laid near to the assembly
opening of the fuel tank.
♦ The extraction hose is used to extract fuel fumes.
♦ If no exhaust gas extraction system is available, a radial fan
with a displacement greater than 15 m3/h can be used provid‐
ing that motor is not in air flow.
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
♦ Interrupt power supply to fuel system pressurisation pump -
G6- ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations.
♦ Drain fuel tank ⇒ page 20 .

8 Rep. gr.00 - Technical data

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

20 – Fuel supply system

1 Procedure should vehicle be misfu‐
eled
⇒ “1.1 Procedure should vehicle be misfueled”, page 9

1.1 Procedure should vehicle be misfueled

Special tools and workshop equipment required
♦ Fuel identification unit - VAS 6774-

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lkswage es n
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Note

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spec
♦ Misfuelling can cause irreversible damage to the high-pres‐
es, in part or in w

t to the co
sure components, particularly the high-pressure pump, due to
the lack of lubrication otherwise provided by diesel fuel.
♦ Damage due to seizure and metal particles can be expected.

rrectness of i
♦ These particles can also cause further damage in the pressure
l purpos

control valve and injectors.

♦ If in any doubt regarding the fuel quality, take a sample and

nform
ercia

analyse the fuel with the fuel analysis unit - VAS 6774- ⇒ op‐
m

erating instructions .

at
om

ion
c

in t
♦ The fuel analysis unit - VAS 6774- is no substitute for a labo‐
or

his
e

ratory test in warranty cases.

at

do
priv

cum
for

These instructions are intended as a guide through the individual

en
ng

t.
yi
work steps by means of a flowchart, while bearing various condi‐
Co
op py
tions in mind.
t. C rig
gh ht
pyri by
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Was the engine started with the incorrect fuel?
c by lksw
cted agen
Prote AG.
Yes
⇒ “1.1.1 Step 1, engine was started with incorrect fuel”,
page 10 .
No
⇒ “1.1.2 Step 2, engine was not started with incorrect fuel”,
page 10

1. Procedure should vehicle be misfueled 9

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

⇒ “1.1.1 Step 1, engine was started with incorrect fuel”,

page 10
⇒ “1.1.2 Step 2, engine was not started with incorrect fuel”, page
10
⇒ “1.1.3 Step 3, swarf in fuel delivery unit and fuel tank”,
page 11
⇒ “1.1.4 Step 4, no swarf in fuel delivery unit and fuel tank”, page
12
⇒ “1.1.5 Step 5, there are metal particles ginenhigh-pressure
AG. Volkswagen Apump”,
G do
page 12 Vo lksw
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ot
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db ara
⇒ “1.1.6 Step 6, there are noorimetal
se particles in high-pressure nte
pump”, page 12 au
th eo
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1.1.1 Step 1, engine was started with incorrect

ce
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fuel
itte

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ab
ility
Sequence of operations
ot p

wit
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– Remove fuel tank ⇒ page 31 .

h re
hole

spec
– Remove fuel delivery unit and drain ⇒ page 43 .
es, in part or in w

t to the co
– Vehicles with all-wheel drive, remove and purge fuel gauge
sender 2 - G169- with suction-jet pump ⇒ page 50 .

rrectness of i
– Drain fuel tank ⇒ page 20 .
l purpos

– Check fuel tank for metal particles.

– Drain fuel pump reservoir of fuel delivery unit.
nf
ercia

– Carry out a visual inspection for foreign bodies and metal par‐ orm
m

ticles in fuel pump reservoir and on preliminary filter.

atio
om

n in
c

Metal particles found?

or

thi
te

sd
a

Yes
iv

o
r
rp

cu

⇒ “1.1.3 Step 3, swarf in fuel delivery unit and fuel tank”, page
o

m
f

11 .
en
ng

t.
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op py
No
. C rig
ht ht
rig
⇒ “1.1.4 Step 4, no swarf in fuel delivery unit and fuel tank”, py by
o Vo
page 12 .
by c lksw
cted agen
Prote AG.

1.1.2 Step 2, engine was not started with in‐

correct fuel
Sequence of operations
– If fitted, disconnect electrical connector on supplementary fuel
pump - V393- .
– Remove fuel tank ⇒ page 31 .
– Remove fuel delivery unit and drain ⇒ page 43 .
– Check strainer and clean if soiled.
– Vehicles with all-wheel drive, remove and purge fuel gauge
sender 2 - G169- with suction-jet pump ⇒ page 50 .
– Drain fuel tank ⇒ page 20 .
Fuel tank completely empty:
– Clean inside of fuel tank with lint-free cloth.
– Install fuel delivery unit ⇒ page 43 .
– Vehicles with all-wheel drive, install fuel gauge sender 2 -
G169- with suction-jet pump ⇒ page 50 .

10 Rep. gr.20 - Fuel supply system

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

– Install fuel tank ⇒ page 31 .

– Fill fuel tank with 5 litres of diesel fuel.
– Perform bleed fuel system function using ⇒ Vehicle diagnostic
tester.

Note

The fuel pump is now activated. Actuation is restricted to 30 sec‐

onds. Procedure must be repeated until fuel tank is completely
empty.

– Renew fuel filter ⇒ page 58 .

– Fill up vehicle.
– Carry out road test.

1.1.3 Step 3, swarf in fuel delivery unit and fuel

tank
AG. Volkswagen AG d
Special tools and workshop equipment required agen oes
olksw not
y V gu
b ara
♦ Diesel extractor - VAS 5226- rise
d
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au ra
ss c

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nl

pt
du

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itte

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erm

ab
ility
ot p

wit
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h re
hole

spec
es, in part or in w

t to the co
rrectness of i
Sequence of operations
l purpos

– Clean fuel delivery unit and fuel tank with diesel extractor -
VAS 5226- .

nf
ercia

or
– Install fuel delivery unit ⇒ page 43 .

m
m

atio
m

– Fill fuel tank with 5 litres of diesel fuel.

o

n in
or c

thi
e

– Completely empty fuel tank again as described above

t

sd
iva

⇒ page 10 .
o
r
rp

cu
o

m
f

Renew following high-pressure components:

en
ng

t.
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op py
♦ Replace high-pressure pump ⇒ Rep. gr. 23 ; High-pressure t. C rig
gh ht
pump: Removing and installing high-pressure pump . yri
p by
co Vo
by lksw
cted
♦ High-pressure lines ⇒ Rep. gr. 23 ; Injectors/fuel rail; Re‐
agen
Prote AG.
moving and installing high-pressure lines .
♦ Fuel rail including fuel pressure regulating valve - N276- and
fuel pressure sender - G247- ⇒ Rep. gr. 23 ; Injectors/fuel
rail; Removing and installing fuel rail
♦ Injectors ⇒ Rep. gr. 23 ; Injectors/fuel rail (fuel rail); Removing
and installing injectors
♦ Fuel return lines ⇒ Rep. gr. 23 ; Injector units/fuel rail; As‐
sembly overview - fuel rail
♦ Fuel filter ⇒ page 58
– Fill up vehicle.

1. Procedure should vehicle be misfueled 11

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

– Fill/bleed fuel system ⇒ Rep. gr. 23 ; Injection system; Filling/

bleeding fuel system .
– Carry out road test.

1.1.4 Step 4, no swarf in fuel delivery unit and

fuel tank
Sequence of operations
– Fill fuel tank with 5 litres of diesel fuel.
– Completely empty fuel tank again as described above
⇒ page 10 .
– Disconnect electrical connectors.
– Unscrew bolts -arrows-.
– Detach fuel metering valve - N290- -A-.
– Check fuel metering valve - N290- -A- and high-pressure
pump for metal particles.
Metal particles found?
Yes
⇒ “1.1.5 Step 5, there are metal particles in high-pressure
pump”, page 12 .
No
⇒ “1.1.6 Step 6, there are no metal particles in high-pressure
pump”, page 12 .
AG. Volkswagen AG d
agen oes
lksw not
1.1.5 Step 5, there are metal particles in high- Vo gu
by ara
d
ise nte
pressure pump author eo
ra
ss c
Sequence of operations
ce
le
un

pt
an
d

– Replace high-pressure pump ⇒ Rep. gr. 23 ; High-pressure

itte

y li

pump: Removing and installing high-pressure pump .

rm

ab
pe

ility

– Renew high-pressure lines ⇒ Rep. gr. 23 ; Injectors/fuel rail

ot

wit
, is n

(fuel rail): Removing and installing high-pressure lines .

h re
hole

spec

– Renew fuel rail including fuel pressure regulating valve - N276-

es, in part or in w

and fuel pressure sender - G247- ⇒ Rep. gr. 23 ; Injectors/

t to the co

fuel rail: Removing and installing fuel rail .

– Renew injectors ⇒ Rep. gr. 23 ; Injectors/fuel rail; Removing
rrectness of i

and installing injectors

l purpos

– Renew fuel return lines ⇒ Rep. gr. 23 ; Injector units/fuel rail;

Assembly overview - fuel rail
nform
ercia

– Renew fuel filter ⇒ page 58 .

m

– Fill up vehicle.
com

tion in

– Fill/bleed fuel system ⇒ Rep. gr. 23 ; Injection system; Filling/

r
te o

thi

bleeding fuel system .

s
iva

do
r
rp

– Carry out road test.

um
fo

en
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t.
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1.1.6 Step 6, there are no metal particles in
Co
Cop py
t. rig
high-pressure pump
gh ht
pyri by
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co lksw
by
cted agen
– Replace high-pressure pump ⇒ Rep. gr. 23 ; High-pressure Prote AG.
pump: Removing and installing high-pressure pump .
– Renew fuel filter ⇒ page 58 .
– Fill/bleed fuel system ⇒ Rep. gr. 23 ; Injection system; Filling/
bleeding fuel system .

12 Rep. gr.20 - Fuel supply system

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

– Fill up vehicle.
– Carry out road test.

n AG. Volkswagen AG do
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urposes, in part or in wh

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Cop py
t. rig
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by
cted agen
Prote AG.

1. Procedure should vehicle be misfueled 13

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

2 Fuel
⇒ “2.1 Assembly overview - fuel tank”, page 14
⇒ “2.2 Emptying fuel tank”, page 20
⇒ “2.3 Removing and installing fuel tank”, page 31

2.1 Assembly overview - fuel tank

⇒ “2.1.1 Assembly overview - fuel tank, vehicles with front-wheel
drive”, page 14 en AG. V
olkswagen AG
ag does
ol ksw n
⇒ “2.1.2 Assembly boverview
yV - fuel tank, vehicles with
ot gfront-wheel
ua
drive, Caddy Maxi”,
rised
page 16 ran
te
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ut
⇒ “2.1.3 Assembly
ss
a overview - fuel tank, vehicles with four-wheel
ra
c
drive”, page 18

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2.1.1 Assembly overview - fuel tank, vehicles with front-wheel drive
itte

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1 - Union nut

h re
hole

❑ Remove and install us‐

spec
ing union nut tool -
es, in part or in w

t to the co
3217- .
❑ 80 Nm
rrectness of i
2 - Seal
❑ Renew after removal
l purpos

❑ When installing, fit dry in

fuel tank opening.
nf
ercia

❑ Moisten with fuel only

rm
m

when installing flange.

atio
om

n in
c

3 - Fuel delivery unit

or

thi
te

sd

❑ With fuel system pres‐

iva

o
r

surisation pump - G6-

rp

cu
o

m
f

en
ng

❑ Checking fuel system

t.
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pressurisation pump - Cop py
t. rig
G6- ⇒ page 72 . opyri
gh by
Vo
ht

❑ With fuel gauge sender

c by lksw
cted agen
- G- Prote AG.

❑ Removing and installing

fuel gauge sender - G-
⇒ page 48
❑ Note installation posi‐
tion of flange on fuel
tank ⇒ page 17 .
❑ Removing and installing
⇒ page 43
❑ Clean strainer if soiled
4 - Fuel
❑ Removing and installing
⇒ page 31
5 - Earth connection
❑ Ensure firm seating
6 - Bolt
❑ 11 Nm

14 Rep. gr.20 - Fuel supply system

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

7 - Cap
8 - Bolt
❑ Renew after removal
❑ 20 Nm +90°
9 - Securing strap on left
❑ Observe installation position
❑ Mark installation position before removing
10 - Securing strap on right
❑ Observe installation position
❑ Mark installation position before removing
11 - Fuel line
❑ From metering pump - V54- to auxiliary heater
❑ Depending on equipment ⇒ Auxiliary heater, supplementary heater; Rep. gr. 82 ; Fuel supply system;
Overview of fitting locations - fuel supply system .
12 - Fuel supply line
❑ black
❑ To fuel filter
❑ Clipped onto fuel tank
❑ To pull off, press release button on connection
❑ Disconnect plug-in connectors ⇒ page 52
❑ Plug-in connectors must engage »audibly« when joined
❑ Ensure firm seating
❑ Ensure plug-in connector is secured properly by pulling it.
13 - Return line
❑ Blue or with blue marking
❑ From engine
❑ Clipped onto fuel tank agen
AG. Volkswagen AG d
oes
olksw not
❑ To pull off, press release d by Vbutton on connection gu
ara
ise nte
❑ Disconnect plug-in thorconnectors ⇒ page 52 eo
au ra
❑ Plug-in connectors
ss must engage »audibly« when joined c
ce
le

❑ Ensure firm seating

un

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❑ Ensure plug-in connector is secured properly by pulling it.

y li
erm

ab
ility

14 - Fuel line
ot p

wit
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❑ To metering pump - V54- for auxiliary heater

h re
ole,

❑ Depending on equipment ⇒ Auxiliary heater, supplementary heater; Rep. gr. 82 ; Fuel supply system;
spec
urposes, in part or in wh

Overview of fitting locations - fuel supply system .

t to the co

❑ Clipped onto fuel tank

❑ Ensure firm seating
rrectne

15 - Metering pump - V54-

❑ ⇒ Auxiliary heater; Rep. gr. 82 ; Fuel supply system; Overview of fitting locations – fuel supply system .
ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

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pr

cum
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en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2. Fuel 15
 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

2.1.2 Assembly overview - fuel tank, vehicles with front-wheel drive, Caddy Maxi

1 - Union nut
❑ Remove and install us‐
ing union nut tool -
3217- .
❑ 80 Nm
2 - Seal
❑ Renew after removal
❑ When installing, fit dry in
fuel tank opening.
❑ Moisten with fuel only
when installing flange.
3 - Fuel delivery unit
❑ With fuel system pres‐
surisation pump - G6-
❑ Checking fuel system
pressurisation pump -
G6- ⇒ page 72 .
❑ With fuel gauge sender
- G-
❑ Removing and installing
fuel gauge sender - G-
⇒ page 48
❑ Note installation posi‐
tion of flange on fuel
tank ⇒ page 17 .
❑ Removing and installing
⇒ page 43
❑ Clean strainer if soiled
4 - Fuel n AG. Volkswagen AG do
wage
❑ Removing and installing olks es n
ot g
yV
⇒ page 31 d b ua
ran
ir se tee
ho
5 - Clip aut or
ac
ss
❑ Only installed on Caddy
ce
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nl

Maxi
pt
du

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itte

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6 - Earth connection
erm

ab
ility
ot p

❑ Ensure firm seating

wit
, is n

h re

7 - Cap
hole

spec

8 - Bolt
es, in part or in w

t to the co

❑ 11 Nm
9 - Bolt
rrectness of i

❑ Only installed on Caddy Maxi

l purpos

❑ 3 Nm
10 - Securing strap on left
nform
ercia

❑ Observe installation position

m

at

❑ Mark installation position before removing

om

ion
c

in t

11 - Bolt
or

his
ate

❑ Renew after removal

do
priv

cum

❑ 20 Nm +90°
for

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by

16
cted agen
Prote AG.
Rep. gr.20 - Fuel supply system
 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

12 - Securing strap on right

❑ Observe installation position AG. Volkswagen AG d
agen
❑ Mark installation position beforeVoremoving
lksw
oes
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13 - Fuel line ris
e an
tee
tho or
❑ From metering pumpss-aV54- u
to auxiliary heater ac
❑ Depending on equipment ⇒ Auxiliary heater, supplementary heater; Rep. gr. 82 ; Fuel supply system;

ce
le
un

pt
Overview of fitting locations - fuel supply system .

an
d
itte

y li
❑ Ensure firm seating
rm

ab
pe

ility
14 - Fuel supply line
ot

wit
, is n

h re
❑ black
hole

spec
❑ To fuel filter
es, in part or in w

t to the co
❑ Clipped onto fuel tank
❑ To pull off, press release button on connection
❑ Disconnect plug-in connectors ⇒ page 52

rrectness of i
❑ Plug-in connectors must engage »audibly« when joined
l purpos

❑ Ensure firm seating

❑ Ensure plug-in connector is secured properly by pulling it.

nform
ercia

15 - Return line
m

a
com

tio
❑ Blue or with blue marking

n in
r
te o

❑ From engine

thi
s
iva

do
❑ Clipped onto fuel tank
r
rp

cum
fo

❑ To pull off, press release button on connection

en
ng

t.
yi Co
❑ Disconnect plug-in connectors ⇒ page 52 Cop py
t. rig
gh
❑ Plug-in connectors must engage »audibly« when joined
ht
pyri by
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❑ Ensure firm seating Prote
cted AG.
agen

❑ Ensure plug-in connector is secured properly by pulling it.

16 - Fuel line
❑ To metering pump - V54- for auxiliary heater
❑ Depending on equipment ⇒ Auxiliary heater, supplementary heater; Rep. gr. 82 ; Fuel supply system;
Overview of fitting locations - fuel supply system .
❑ Clipped onto fuel tank
❑ Ensure firm seating
17 - Metering pump - V54-
❑ ⇒ Auxiliary heater; Rep. gr. 82 ; Fuel supply system; Overview of fitting locations – fuel supply system .

Installation position of fuel delivery unit

Mark on flange -1- must align with mark on fuel tank -arrow-.

2. Fuel 17
 AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
Caddy 2016 ➤ ut
h o eo
ra
a
Fuel supply system
ss - Diesel engines - Edition 04.2019 c

ce
e
nl

pt
du
2.1.3 Assembly overview - fuel tank, vehicles with four-wheel drive

an
itte

y li
erm

ab
ility
ot p

wit
1 - Fuel supply line
, is n

h re
❑ black
hole

spec
❑ To fuel filter
es, in part or in w

t to the co
❑ Clipped onto fuel tank
❑ To pull off, press release
button on connection

rrectness of i
❑ Disconnect plug-in con‐
l purpos

nectors ⇒ page 52
❑ Plug-in connectors must

nf
ercia

engage »audibly« when

orm
joined
m

atio
m

❑ Ensure firm seating

o

n in
or c

❑ Ensure plug-in connec‐

thi
te

sd
a

tor is secured properly

iv

o
r
rp

cu
by pulling it.
o

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f

en
ng

t.
yi
2 - Fuel line
Co
Cop py
.
❑ To metering pump -
ht rig
rig ht
by
V54- for auxiliary heater copy Vo
by lksw
cted agen
❑ Depending on equip‐ Prote AG.
ment ⇒ Auxiliary heater,
supplementary heater;
Rep. gr. 82 ; Fuel sup‐
ply system; Overview of
fitting locations - fuel
supply system .
❑ Clipped onto fuel tank
❑ Ensure firm seating
3 - Return line
❑ Blue or with blue mark‐
ing
❑ From engine
❑ Clipped onto fuel tank
❑ To pull off, press release
button on connection
❑ Disconnect plug-in connectors ⇒ page 52
❑ Plug-in connectors must engage »audibly« when joined
❑ Ensure firm seating
❑ Ensure plug-in connector is secured properly by pulling it.
4 - Filler neck
5 - Clip
❑ Only installed on Caddy Maxi
6 - Earth connection
❑ Ensure firm seating
7 - Bolt
❑ 11 Nm
8 - Cap
❑ Renew seal if damaged.
9 - Bolt
❑ Only installed on Caddy Maxi
❑ 3 Nm

18 Rep. gr.20 - Fuel supply system

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

10 - Connecting hose with screw-type clip

❑ 3.5 Nm
AG. Volkswagen AG d
11 - Fuel wage
n oes
Volks not
gu
❑ Removing and installing ⇒
ed page 31
by ara
nte
is
or eo
12 - Sleeve au
th ra
ss c
❑ Observe installation position

ce
le
un

pt
❑ Mark installation position before removing.

an
d
itte

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rm

ab
13 - Bolt
pe

ility
❑ Renew after removal
ot

wit
, is n

h re
❑ 20 Nm +90°
hole

spec
14 - Heat shield
es, in part or in w

t to the co
15 - Bolt
❑ 25 Nm

rrectness of i
16 - Seal
l purpos

❑ Renew after removal

❑ When installing, fit dry in fuel tank opening.

nform
ercia

❑ Moisten with fuel only when installing flange.

m

a
17 - Fuel gauge sender - G-
com

tion in
❑ Removing and installing fuel gauge sender - G- ⇒ page 49
r
te o

thi
s
iva

do
18 - Locking ring
r
rp

cum
fo

❑ Fuel gauge sender - G-

en
ng

t.
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❑ 110 Nm . Cop py
rig
ht ht
rig
19 - Locking ring py by
co Vo
by lksw
❑ Fuel delivery unit cted agen
Prote AG.
❑ 110 Nm
20 - Fuel delivery unit
❑ With fuel system pressurisation pump - G6-
❑ Checking fuel system pressurisation pump - G6- ⇒ page 72 .
❑ With fuel gauge sender - G-
❑ Removing and installing fuel gauge sender - G- ⇒ page 48
❑ Note installation position of flange on fuel tank ⇒ page 17 .
❑ Removing and installing ⇒ page 43
❑ Clean strainer if soiled

Installation position of flange for fuel delivery unit and fuel gauge
sender 2 - G169-
Flange lug -arrows- only fits in one position in mounting on fuel
tank.

2. Fuel 19
 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

2.2 Emptying fuel tank

⇒ “2.2.1 Emptying fuel tank, front-wheel drive”, page 20
⇒ “2.2.2 Emptying fuel tank, all-wheel drive”, page 25

2.2.1 Emptying fuel tank, front-wheel drive

Emptying fuel tank when fuel pump is intact ⇒ page 20 .
Emptying fuel tank if defective pump is more than 3/4 full
⇒ page 22
Emptying fuel tank if defective pump is less than 3/4 full
⇒ page 23 wage
n AG. Volkswagen AG do
e ks s no
Vol t gu
Emptying fuel tank when fuel pump is intact
ed
by ara
is nte
or eo
Special tools and workshop equipment
au
th required ra
ss c
♦ Fuel extractor - VAS 5190-

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

♦ Adapter for fuel extraction - VAS 5190/3-

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

♦ Vehicle diagnostic, testing and information system - VAS

5051B-

20 Rep. gr.20 - Fuel supply system

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

Note

If the fuel extraction uniten- AVAS

G. Vol5190- isAstill
kswagen G do
fitted with the extrac‐
tion hose with a solid
olksw tip, the extraction hose
ag es must
not be replaced
with the version
ed by with a screwed tip.
V gu
ara
ris nte
utho eo
– Unscrew
ss
a tip -1- from extraction hose of fuel extractionr acunit -
VAS 5190- .

ce
le
un

pt
an
d

– Screw fuel extraction adapter - VAS 5190 /2- from fuel extrac‐
itte

y li
tion adapter set - VAS 5190 /10- onto extraction hose.
rm

ab
pe

ility
ot

wit
, is n

WARNING

h re
hole

spec
Danger of burning from very hot fuel!
es, in part or in w

t to the co
♦ In extreme cases the fuel lines and the fuel can reach a
temperature of 100°C. Allow the fuel to cool down before
disconnecting the lines - risk of scalding.

rrectness of i
♦ Wear protective gloves.
l purpos

♦ Wear protective goggles.

nform
ercia

Risk of injury due to highly-pressurised fuel!

m

♦ To release pressure in fuel system, place clean cloth a

com

tion in
around connection and carefully undo connection.
r
te o

thi
s
iva

do
r
rp

cum
fo

– Pull off fuel supply line -2-

en
ng

t.
yi Co
⇒ “4.1 Separating plug-in connectors”, page 52 .
t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2. Fuel 21
 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

– Connect fuel extractor - VAS 5190- with adapter for fuel ex‐
tractor - VAS 5190 /3 - to fuel supply line.
– Remove cap from fuel filler neck.
– Switch on ignition.
– Connect vehicle diagnosis, testing and information system -
VAS 5051B- or vehicle diagnosis, testing and information
system - VAS 5052 A- Carry out in the guided function “Empty
fuel system”.

Note

The fuel pumps are now actuated. The vehicle diagnostic tester
shows the progress of the drainage.

– Open shut-off tap on fuel extractor - VAS 5190- until fuel tank
is emptied.
– When the fuel tank is empty, stop the function to prevent the
fuel pump from running »dry«.
AG. Volkswagen A
G do 3
Emptying fuel tank if defective
lksw
agenpump is more than es n/4 full
o
o t gu
yV
db ara
rise nte
Special tools and
tho workshop equipment required eo
s au ra
c
♦ Fuel extractor
s - VAS 5190-
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
ercia

Caution
m

at
om

Secure earth wire of fuel extractor - VAS 5190- to a bare metal

ion
c

part of the body.

in t
or

his
ate

do
priv

cum
or

Sequence of operations
f

en
ng

t.
yi Co
op
– Remove cone piece -2- from shaft -1- of fuel extractor - C py
t. rig
VAS 5190- .
gh ht
pyri by
Vo
o
by c lksw
– Make a mark -arrow- on hose with insulating tape at distance Prote
cted AG.
agen
-a- = 1700 mm from end of extraction hose.
– Open fuel tank flap.
– Remove cap from fuel filler neck.

22 Rep. gr.20 - Fuel supply system

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

Note

A ball valve -2- is located at the bottom of the filler neck in the fuel
tank -1-; take care not to damage it with the extraction hose -3-.
Therefore push hose into filler neck only as far as marking
-arrow-.

– Screw shaft -1- of fuel extractor - VAS 5190- onto fuel tank
filler neck.
– Push extraction hose into fuel tank until marking on hose
. Volkswag
-arrow- coincides
ksw
awith shaft [Link] AG does
gen AG
ol not
yV gu
– Drain fuel ed tank as far as possible.
b ara
nte
oris eo
h
– Pull
sa
uextraction
t
hose out carefully. ra
c
s
ce
le
un

pt
an
d

Note
itte

y li
rm

ab
pe

ility

♦ When no more fuel is extracted, the tank is emptied just

ot

wit

enough for the sender flange to be opened without danger.

, is n

h re
hole

♦ If fuel tank has to be drained fully, proceed as follows.

spec
es, in part or in w

t to the co

Emptying fuel tank if defective pump is less than 3/4 full

rrectness of i

Special tools and workshop equipment required

l purpos

♦ Key for union nut - 3217-

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2. Fuel 23
 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

♦ Torque wrench (40 … 200 Nm) - V.A.G 1332-

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du
♦ Fuel extractor - VAS 5190-

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

o
♦ Adapter for fuel extraction - VAS 5190/3-

rm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sequence of operations
– Remove fuel tank ⇒ page 31 .

WARNING

Wrap a cloth around the connection before loosening hose

connections.

24 Rep. gr.20 - Fuel supply system

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

– Release connector -arrow- and pull off from flange -1-.

– Remove fuel lines -1- and -2-. To do this, press release buttons
⇒ page 52 .
– On vehicles with auxiliary heater, remove fuel lines -3-.

AG. Volkswagen AG d
agen oes
lksw not
– Unscrew union nut -1- using union nut tool - 3217- . by
Vo gu
ara
ed
is nte
– Raise sender flange. ut
hor eo
ra
s a c
– Insert suction hose of fuel extractor - VAS 5190-s as far as

ce
e

possible into fuel tank. Extract fuel.

nl

pt
du

an
itte

y li
If fuel tank only needs to be drained, install sender flange again.
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion

2.2.2 Emptying fuel tank, all-wheel drive

c

in t
or

his
ate

Emptying fuel tank when fuel pump is intact ⇒ page 25 .

do
priv

cum
for

Emptying fuel tank if defective pump is more than 3/4 full

en
ng

t.
yi Co
⇒ page 27 Cop py
t. rig
gh ht
yri
Emptying fuel tank if defective pump is less than 3/4 full
p by
o Vo
by c lksw
⇒ page 29
cted agen
Prote AG.

Emptying fuel tank when fuel pump is intact

Special tools and workshop equipment required

2. Fuel 25
 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

♦ Fuel extractor - VAS 5190-

♦ Adapter for fuel extraction - VAS 5190 /3-

G. Volkswagen
♦ Vehicle diagnostic, testinglksand
wageinformation system
nA AG do
e-sVAS
not
5051B- by Vo gu
a
ed ran
oris tee
th or
au ac
ss
ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co

Sequence of operations
rrectne

WARNING
ss o
cial p

Fuel supply line is pressurised. Wear protective goggles and

inform

protective clothing to avoid injury and contact with the skin.

mer

Wrap a cloth around the connection before loosening hose

atio
m

connections. Then release pressure by carefully pulling hose

o

n
c

i
or

off connection.
thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
op
Note C py
t. rig
gh ht
pyri by
Vo
o
Supplementary fuel pump - V393- not fitted on all engine types. by c lksw
cted agen
Prote AG.

26 Rep. gr.20 - Fuel supply system

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

– Remove fuel supply line -2-

⇒ “4.1 Separating plug-in connectors”, page 52 .

– Connect fuel extractor - VAS 5190- with adapter for fuel ex‐
tractor - VAS 5190 /3 - to fuel supply line.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un

pt
an
d
itte

y li
erm

ab

– If fitted, separate connector -A- to supplementary fuel pump -

ility
ot p

V393- .
wit
is n

h re

– Switch on ignition.
ole,

spec
urposes, in part or in wh

– Remove cap from fuel filler neck.

t to the co

– Connect vehicle diagnostic tester and perform guided function

“Draining fuel system”.
rrectne

Note
ss o
cial p

The fuel pumps are now actuated. The vehicle diagnostic tester
inform

shows the progress of the drainage.

mer

atio
om

– Open shut-off tap on fuel extractor - VAS 5190- until fuel tank
c

i
or

is emptied.
thi
te

sd
iva

o
r

– When the fuel tank is empty, stop the function to prevent the
p

cum
r
fo

fuel pump from running »dry«.

en
ng

t.
yi Co
op
Emptying fuel tank if defective pump is more than 3/4 full
C py
ht. rig
rig ht
py by
co Vo
by lksw
Special tools and workshop equipment required cted agen
Prote AG.

2. Fuel 27
 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

♦ Fuel extractor - VAS 5190-

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
♦ Adapter for fuel extraction - VAS 5190/3-

itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

Caution

ion
c

in t
or

his
e

Secure earth wire of fuel extractor - VAS 5190- to a bare metal

at

do
riv

part of the body.

p

cum
for

en
ng

t.
yi Co
op
– Remove cone piece -2- from shaft -1- of fuel extractor -
C py
ht. rig
VAS 5190- .
rig ht
py by
co Vo
by lksw
cted
– Make a mark -arrow- on hose with insulating tape at distance
agen
Prote AG.
-a- = 1700 mm from end of extraction hose.
– Open fuel tank flap.
– Remove cap from fuel filler neck.

28 Rep. gr.20 - Fuel supply system

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

A ball valve -2- is located at the bottom of the filler neck in the fuel
tank -1-; take care not to damage it with the extraction hose -3-.
Therefore push hose into filler neck only as far as marking
-arrow-.

– Screw shaft -1- of fuel extractor - VAS 5190- onto fuel tank
filler neck.
– Push extraction hose into fuel tank until marking on hose
-arrow- coincides with shaft end.
– Drain fuel tank as far as possible.
– Pull extraction hose out carefully.

Note
AG. Volkswagen AG d
agen oes
lksw not
♦ When no more fuel is extracted, the tank is demptiedby
Vo just gu
ara
enough for the sender flange to be opened oris without danger.
e nte
h eo
ut
If fuel tank has to be drained fully, proceed as follows
ra
♦ ss a c
⇒ page 29 .
ce
le
un

pt
an
d
itte

y li
Emptying fuel tank if defective pump is less than 3/4 full
rm

ab
pe

ility
ot

wit
, is n

Special tools and workshop equipment required

h re
hole

spec

♦ Torque wrench (40 … 200 Nm) - V.A.G 1332-

es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

2. Fuel 29
 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019 n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d
♦ Fuel extractor - VAS 5190- o
ir se
ran
tee
th or
au ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
♦ Adapter for fuel extraction - VAS 5190/3-
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

WARNING

Fuel tank must not be more than 1/4 full.

Fuel supply line is pressurised. Wear protective goggles and
protective clothing to avoid injury and contact with the skin.
Wrap a cloth around the connection before loosening hose
connections. Then release pressure by carefully pulling hose
off connection.

– Lower fuel tank

⇒ “2.3.2 Removing and installing fuel tank, four-wheel drive”,
page 35 .
– Release connector -arrow- and pull off from flange -1-.

30 Rep. gr.20 - Fuel supply system

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

– Disconnect fuel lines -1- and -2- on flange. Separate plug-in

connectors
⇒ “4.1 Separating plug-in connectors”, page 52 .
– If fitted, remove fuel line -3- leading to metering pump - V54-
for auxiliary heater from sealing flange.

– Open locking ring using wrench - T10202- .

– Carefully lift flange of fuel delivery unit.
– Insert suction hose of fuel extractor - VAS 5190- as far as
possible into fuel tank. Extract fuel.

AG. Volkswagen AG d
Note lksw
agen oes
not
Vo gu
by ara
d
In order to extract the remaining fuel from the 2nd chamber,rise the nte
ho eo
fuel tank has to be lowered and fuel gauge sender 2 - sG169-
aut
lifted ra
c
up ⇒ page 50 . s

ce
e
nl

pt
du

an
itte

If fuel tank only needs to be drained, install sender flange again.

y li
erm

ab
ility
ot p

2.3 Removing and installing fuel tank

wit
, is n

h re
hole

⇒ “2.3.1 Removing and installing fuel tank, front-wheel drive”,

spec
page 31
es, in part or in w

t to the co
⇒ “2.3.2 Removing and installing fuel tank, four-wheel drive”,
page 35

rrectness of i
2.3.1 Removing and installing fuel tank, front-
l purpos

wheel drive
Special tools and workshop equipment required

nf
ercia

orm
♦ Torque wrench (5 to 50 Nm) - V.A.G 1331-
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2. Fuel 31
 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

♦ Torque wrench - V.A.G 1332-

♦ Engine and gearbox jack - VAS 6931-

AG. Volkswagen AG d
agen oes
lksw not
Removing d byV
o gu
ara
ise nte
r
– Disconnect battery ⇒ Rep. gr. 27 ; Battery; Disconnecting
ut
ho and eo
ra
connecting battery . ss a c

ce
e
nl

– Drain fuel tank ⇒ page 20 .

pt
du

an
itte

y li
– Unclip rubber cup from filler neck.
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
– Unscrew bolts -3- on filler neck -1-.
rrectness of i

– Detach rear left wheel ⇒ Running gear, axles, steering; Rep.

l purpos

gr. 44 ; Wheels, tyres; Wheel change .

– Remove rear left wheel housing liner ⇒ General body repairs,
nform
ercia

exterior; Rep. gr. 66 ; Wheel housing liner; Removing and

m

installing rear wheel housing liner .

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

32 Rep. gr.20 - Fuel supply system

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

– On Caddy Maxi, unscrew bolt -arrow- for filler neck on longi‐

tudinal member.
. Volkswage
– Remove rear silencer ⇒ Rep. gr. 26 ; Exhaust gen AG
apipes/silencers;
n AG d
oes
lksw not
Removing and installing rear silencer b. y Vo gu
a
ed ran
ris
– If fitted, remove heat shield. tho
tee
or
au ac
ss

ce
le
WARNING

un

pt
an
d
itte

y li
erm
♦ The fuel and the fuel lines in the fuel system can become

ab
ility
very hot (danger of scalding)!
ot p

wit
is n

♦ The fuel system is also under pressure! Before opening

h re
ole,

the system, place a cloth around the connection and re‐

spec
urposes, in part or in wh

duce pressure by carefully loosening the connection!

t to the co
♦ Wear eye and hand protection when performing any type
of repair work on the fuel system!

rrectnes
– Separate fuel lines -1- and -2- at front right of fuel tank

s o
cial p

⇒ “4.1 Separating plug-in connectors”, page 52 .

f inform
mer

– On vehicles with auxiliary heater, detach fuel line -1- from hose

atio
-2- on metering pump ⇒ Rep. gr. 82 ; Fuel supply; Removing
om

and installing metering pump - V54-

n
c

i
or

n thi
e

– Support fuel tank with engine and gearbox jack - VAS 6931- .
t

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2. Fuel 33
 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

– Unscrew bolts -arrows-, and remove securing straps -2-.

– Slowly lower engine and gearbox jack - VAS 6931- until 5-pin
connector can be pulled off the fuel delivery unit.
– Continue to lower fuel tank -1-. While doing so, rotate fuel tank
and feed filler neck between the leaf springs and the body.
AG. Volkswagen AG d
Installing lksw
agen oes
not
o
yV gu
Install in reverse order of removal. During this
risedprocedure, observe
b ara
nte
the following: ut
ho eo
ra
s a c
s

ce
le
Caution
un

pt
an
d
itte

y li
erm

ab
The fuel pump must not be allowed to run when the fuel tank

ility
ot p

is empty, as this may cause deflagrations.

wit
is n

h re
The fuel tank must contain at least 5 litres of fuel.
ole,

spec
urposes, in part or in wh

t to the co
– If fitted, check that metering pump - V54- is firmly seated.
– Install breather lines and fuel lines free of kinks.

rrectne
– Ensure that the filler neck of the fuel tank is correctly inserted
into the opening in the body.

ss o
– Position the fuel tank together with securing strap on under‐
cial p

f in
body, using the engine and gearbox jack - VAS 6931- .

form
mer

– Note position of securing strap.

atio
om

n
c

– After installing fuel tank, check that the supply, return and

i
or

n thi
e

breather lines are still clipped onto the fuel tank.

t

sd
iva

o
pr

c
– Ensure that bracket for exhaust system is seated correctly ⇒
um
r
fo

Rep. gr. 26 ; Exhaust pipes/silencers; Assembly overview - en

ng

t.
yi Co
silencers . ht. Cop py
rig
rig ht
– Ensure that line connections are tight. py by
co Vo
by lksw
cted agen
– Ensure connections are secured properly by pulling. Prote AG.

34 Rep. gr.20 - Fuel supply system

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

– Check whether there are signs of oxidation on the earth wire

of the connectors, remove if necessary.
– Check installation position of earth connection.
• Ensure that connector -2- is seated securely on metal ring
-3-. AG. Volkswagen n AG do
lks and secured wage es n
• Contact tab -1- must be hooked into fuel tank Vo-4- ot g
by ua
by means of spacer bush -5-. ris
ed ran
tee
tho or
– Check the connection of the metals aring
u on the fuel filler neck ac
by measuring between the ring and
s
a bare metal part of the

ce
le
body using an ohmmeter.
un

pt
an
d
itte

y li
• Specification: approx. 0 ohm.
rm

ab
pe

ility
• If the specification is not attained, there is a risk of explosion
ot

wit
, is n

due to electrostatic discharge.

h re
hole

spec
– Fill fuel tank with at least 5 litres of fuel.
es, in part or in w

t to the co
Specified torques
♦ Fuel tank ⇒ “2.1 Assembly overview - fuel tank”, page 14

rrectness of i
♦ ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Assembly overview
- silencers
l purpos

♦ ⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit;

Removing and installing tank flap unit

nform
mercia

a
2.3.2 Removing and installing fuel tank, four-
com

tion in
wheel drive
r
te o

thi
s
iva

do
r
rp

cum
fo

Caution

en
ng

t.
yi Co
Cop py
The fuel pump must not be allowed to run when the fuel tank
t. rig
gh ht
yri
is empty, as this may cause deflagrations.
p by
co Vo
by lksw
cted agen
The fuel tank must contain at least 5 litres of fuel.
Prote AG.

Note

♦ Before carrying out further work, disconnect the battery. Be‐

fore doing so, check whether a coded radio is fitted in the
vehicle. Obtain anti-theft coding beforehand if necessary.
♦ When lowering fuel tank, guide it carefully to prevent damage.

Special tools and workshop equipment required

♦ Torque wrench - V.A.G 1332-

2. Fuel 35
 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

♦ Fuel tank sender unit tool - T10202-

Removing
– Check whether a coded radio is fitted. If so, obtain anti-theft
coding.
– Disconnect earth cable at battery with ignition switched off ⇒
Rep. gr. 27 ; Disconnecting and connecting battery .
– Drain fuel tank with fuel extractor - VAS 5190- ⇒ page 20 .
olkswagen AG
en AG. V
– Unclip rubber cup from filler oneck.
lksw
ag does
not
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urposes, in part or in wh

t to the co

– Unscrew bolts -3- on filler neck -1-.

rrectne

– Remove left rear wheel.

s

– Remove rear left wheel housing liner ⇒ General body repairs,

s o

exterior; Rep. gr. 66 ; Wheel housing liner; Removing and

cial p

f in

installing rear wheel housing liner .

form
mer

atio
om

n
c

i
or

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en
ng

t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

36 Rep. gr.20 - Fuel supply system

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

– On Caddy Maxi, unscrew bolt -arrow- for filler neck on longi‐

tudinal member.

WARNING

♦ The fuel and the fuel lines in the fuel system can become
very hot (danger of scalding)!
♦ The fuel system is also under pressure! Before opening
the system, place a cloth around the connection and re‐
duce pressure by carefully loosening the connection!
♦ Wear eye and hand protection when performing any type
of repair work on the fuel system!

– Separate fuel lines -1- and -2- at front right of fuel tank
⇒ “4.1 Separating plug-in connectors”, page 52 .
– On vehicles with auxiliary heater, detach fuel line -1- from hose
-2- on metering pump ⇒ Rep. gr. 82 ; Fuel supply; Removing
and installing metering pump - V54-
– Remove rear silencer ⇒ Rep. gr. 26 ; Exhaust pipes/silencers;
Removing and installing rear silencer .
– If fitted, remove heat shield.

– Unbolt both shock absorbers on rear axle -arrow-. AG. Volkswagen A

agen G do
w es n
olks ot g
byV ua
ed ran
ris tee
tho or
au ac
ss
ce
e
nl

pt
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itte

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ab
ility
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wit
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hole

spec
es, in part or in w

t to the co

– Unhook breather lines -2- and -3- from rear final drive out of
carrier plate -1-.
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by
cted agen
Prote AG.

2. Fuel 37
 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

– Remove carrier plate -1-.

– Unscrew bolts -arrows- and lower fuel tank as far as propshaft.
– Pull off both connectors on flanges. AG. Volkswagen AG d
agen oes
olksw not
byV gu
WARNING rised ara
nte
ho eo
aut ra
♦ The fuel and the fuel lines in the fuel system can
s become
s c
very hot (danger of scalding)!

ce
le
un

pt
an
d
itte
♦ The fuel system is also under pressure! Before opening

y li
erm

ab
the system, place a cloth around the connection and re‐

ility
ot p
duce pressure by carefully loosening the connection!

wit
is n

h re
♦ Wear eye and hand protection when performing any type
ole,

of repair work on the fuel system!

spec
urposes, in part or in wh

t to the co
– Pull off fuel lines from both flanges
⇒ “4.1 Separating plug-in connectors”, page 52 .

rrectne
WARNING

ss o
cial p

f in
Fuel tank is tilted to side during further work. To do this, fuel

form
mer

tank must be completely drained.

atio
om

n
c

i
or

n thi
2nd chamber still full of fuel:
te

sd
iva

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pr

cum
r
fo

– Loosen locking ring using wrench - T10202- .

en
ng

t.
yi Co
op
– Lift up fuel gauge sender 2 - G169- . C py
ht. rig
rig ht
– Insert suction hose of fuel extractor - VAS 5190- as far as
py by
co Vo
by lksw
possible into fuel tank and extract remaining fuel. Prote
cted AG.
agen

Fuel tank completely drained:

– Pull off breather line on fuel tank and unclip from fuel tank.
– Lower rear axle approximately 20 mm.

– Open screw-type clip -3- and pull off connecting hose -4- wit
filler neck from fuel tank -1-.
– Unscrew bolts -arrows- and lower fuel tank -1- slightly.

Note

When lowering fuel tank, guide it carefully to prevent damage.

38 Rep. gr.20 - Fuel supply system

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

– With fuel tank in position shown remove on left-hand side.

Installing
Install in reverse order of removal. During this procedure, observe
the following:

Caution

The fuel pump must not be allowed to run when the fuel tank
is empty, as this may cause deflagrations.
The fuel tank must contain at least 5 litres of fuel. AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
d
♦ When inserting fuel delivery unit, ensure that fuelhogauge
ris
e
send‐ nte
eo
er 2 - G169- is not bent. aut ra
c
s s
♦ Renew seal.

ce
le
un

pt
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d
itte

♦ Insert seal for fuel delivery unit dry into opening of fuel tank.

y li
rm

ab
pe

♦ Moisten seal with fuel only when installing fuel delivery unit.

ility
ot

wit
, is n

♦ Install breather lines and fuel lines free of kinks.

h re
hole

spec
♦ Do not interchange supply line and return line (return line blue
es, in part or in w

or with blue marking, supply line black).

t to the co
♦ Ensure that line connections are tight.
♦ After installing fuel delivery unit, check that the supply, return

rrectness of i
and breather lines are still clipped onto the fuel tank.
l purpos

– Check whether there are signs of oxidation on the earth wire

of the connectors, remove if necessary.

nform
ercia

– Check installation position of earth connection.

m

a
com

tion in
• Ensure that connector -2- is seated securely on metal ring
r
te o

thi
-3-.

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iva

do
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rp

• Contact tab -1- must be hooked into fuel tank -4- and secured

cum
fo

by means of spacer bush -5-.

en
ng

t.
yi Co
op
– Check the connection of the metal ring on the fuel filler neck
C py
ht. rig
by measuring between the ring and a bare metal part of the
rig ht
py by
o Vo
body using an ohmmeter. by c lksw
cted agen
Prote AG.
• Specification: approx. 0 ohm.
• If the specification is not attained, there is a risk of explosion
due to electrostatic discharge.
– Fill fuel tank with at least 5 litres of fuel.
– Observe installation position of fuel supply line to supplemen‐
tary heater ⇒ Auxiliary heater, supplementary heater; Rep.
gr. 82 ; Fuel supply system .
– After installing fuel delivery unit, check that supply and return
lines are still clipped onto fuel tank.
Specified torques
♦ Fuel tank ⇒ “2.1 Assembly overview - fuel tank”, page 14 .
♦ Silencer with mountings and tunnel cross-piece ⇒ Rep. gr.
26 ; Exhaust pipes/silencers; Assembly overview - silencers .

2. Fuel 39
 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

3 Fuel delivery unit, fuel gauge sender

⇒ “3.1 Assembly overview - fuel delivery unit/fuel gauge sender”,
page 40
⇒ “3.2 Removing and installing fuel delivery unit, fuel gauge send‐
er”, page 43
⇒ “3.3 Removing and installing fuel gauge sender G ”,
page 48

3.1 Assembly overview - fuel delivery unit/

fuel gauge sender
⇒ “3.1.1 Assembly overview - fuel delivery unit/fuel gauge sender,
vehicles with front-wheel drive”, page 40
⇒ “3.1.2 Assembly overview - fuel delivery unit/fuel gauge sender,
vehicles with four-wheel drive”, page 42

3.1.1 Assembly overview - fuel delivery unit/fuel gauge sender, vehicles with
front-wheel drive

1 - Fuel delivery unit

❑ With fuel system pres‐
surisation pump - G6-
❑ Checking fuel system
pressurisation pump -
G6- ⇒ page 72 .
❑ With fuel gauge sender
- G- n AG. Volkswagen AG do
swage es n
❑ Removing and installing y Vo lk ot g
ua
fuel gauge sender - G-rised b ran
tee
⇒ page 48 utho
or
a ac
❑ Note installation posi‐
ss
ce
e

tion of flange on fuel

nl

pt
du

tank ⇒ page 17 .
an
itte

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erm

❑ Removing and installing

ab
ility

⇒ page 43
ot p

wit
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❑ Clean strainer if soiled

h re
hole

spec

2 - Seal
es, in part or in w

❑ Renew after removal

t to the co

❑ When installing, fit dry in

fuel tank opening.
rrectness of i

❑ Moisten with fuel only

when installing flange.
l purpos

3 - Union nut
nform
ercia

❑ Remove and tighten

with wrench - T10202- .
m

at
om

io

❑ 80 Nm
n
c

in t
or

his
e

4 - Fuel line
at

do
riv

❑ For vehicles with auxili‐

p

cum
or

ary heater; from auxili‐

f

en
ng

t.
yi
ary heater metering
Co
op py
pump - V54- t. C rig
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yri by
❑ Do not kink cop Vo
by lksw
cted agen
❑ Installation position ⇒ Auxiliary heater, supplementary heater; Rep. gr. 82 ; Fuel supply system; Over‐ Prote AG.
view of fitting locations - Fuel supply system .
❑ To pull off, press release button on connection

40 Rep. gr.20 - Fuel supply system

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019
❑ Plug-in connectors must engage »audibly« when joined
❑ Ensure firm seating
❑ Ensure plug-in connector is secured properly by pulling it.
❑ Disconnect plug-in connectors ⇒ “4.1 Separating plug-in connectors”, page 52
❑ Ensure connections are secured properly by pulling.
5 - Fuel supply line
❑ black
❑ To engine
❑ Do not kink
❑ To pull off, press release button on connection
❑ Plug-in connectors must engage »audibly« when joined
❑ Ensure firm seating
❑ Ensure plug-in connector is secured properly by pulling it.
❑ Disconnect plug-in connectors ⇒ “4.1 Separating plug-in connectors”, page 52
6 - Return line
❑ Blue or with blue marking agen
AG. Volkswagen AG d
oes
lksw not
❑ Clipped onto d byfuel
Vo
tank gu
ara
se nte
❑ Do notthkink
ori
eo
u ra
❑ To spull
s a off, press release button on connection c ce
le

❑ Plug-in connectors must engage »audibly« when joined

un

pt
an
d
itte

❑ Ensure firm seating

y li
erm

ab

❑ Ensure plug-in connector is secured properly by pulling it.

ility
ot p

wit

❑ Disconnect plug-in connectors ⇒ “4.1 Separating plug-in connectors”, page 52

is n

h re
ole,

7 - Electrical connector
spec
urposes, in part or in wh

❑ For fuel pump control unit - J538- .

t to the co

❑ Ensure proper engagement; check if connector is engaged correctly by pulling.

8 - Fuel gauge sender - G-
rrectne

❑ Checking ⇒ Vehicle diagnostic tester

❑ Removing and installing ⇒ page 48
ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

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pr

cum
r
fo

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by
cted agen
Prote AG.

3. Fuel delivery unit, fuel gauge sender 41

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019
AG. Volkswagen AG d
agen oes
ksw
3.1.2 Assembly overview - fuel delivery unit/fuel gauge sender, vehicles with four- d by
Vol not
gu
ara
wheel drive ise nte
or eo
h
aut ra
ss c

ce
le
un
1 - Fuel line

pt
an
d
itte

y li
❑ For vehicles with auxili‐ rm

ab
ary heater; from auxili‐
pe

ility
ary heater metering
ot

wit
, is n

pump - V54-

h re
hole

❑ Do not kink

spec
es, in part or in w

❑ Installation position ⇒

t to the co
Auxiliary heater, supple‐
mentary heater; Rep.
gr. 82 ; Fuel supply sys‐

rrectness of i
tem; Overview of fitting
locations - Fuel supply
l purpos

system .
❑ Ensure firm seating

nform
ercia

2 - Return line
m

a
com

ti
❑ Blue or with blue mark‐

on in
ing
r
te o

thi
s
iva

❑ Clipped onto fuel tank

do
r
rp

cum
❑ To pull off, press release
fo

en
g

button on connection
n

t.
yi Co
op py
❑ Plug-in connectors must t. C rig
gh ht
engage »audibly« when yri
p by
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joined
by c lksw
cted agen
Prote AG.
❑ Ensure firm seating
❑ Ensure plug-in connec‐
tor is secured properly
by pulling it.
❑ Disconnect plug-in con‐
nectors
⇒ “4.1 Separating plug-
in connectors”,
page 52
3 - Fuel supply line
❑ To engine
❑ Do not kink
❑ To pull off, press release button on connection
❑ Plug-in connectors must engage »audibly« when joined
❑ Ensure firm seating
❑ Ensure plug-in connector is secured properly by pulling it.
❑ Disconnect plug-in connectors ⇒ “4.1 Separating plug-in connectors”, page 52
4 - Locking ring
❑ Remove and tighten with wrench - T10202- .
❑ 110 Nm
5 - Seal
❑ Renew after removal
❑ When installing, fit dry in fuel tank opening.
❑ Moisten with fuel only when installing flange.
6 - Fuel delivery unit
❑ With fuel system pressurisation pump - G6-
❑ Checking fuel system pressurisation pump - G6- ⇒ page 72 .
❑ With fuel gauge sender - G-

42 Rep. gr.20 - Fuel supply system

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019
❑ Removing and installing fuel gauge sender - G- ⇒ page 48
❑ Note installation position of flange on fuel tank ⇒ page 17 .
❑ Removing and installing ⇒ page 43
❑ Clean strainer if soiled
7 - Fuel gauge sender - G-
❑ Checking ⇒ Vehicle diagnostic tester
❑ Removing and installing ⇒ page 49
Volkswa
8 - Electrical connector agen
AG. gen AG
does
olksw not
❑ For fuel pump control unit - J538- . ed by V gu
ara
is nte
❑ Ensure proper engagement; checkut
hor
if connector is engaged correctly by pulling. eo
a ra
ss c

ce
le
un

pt
an
Installation position of fuel delivery unit
d
itte

y li
rm

ab
• The arrow -3- on the fuel tank must line up with the mark -2-
pe

ility
on the sealing flange -1-.
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
ercia

Fuel lines on fuel delivery unit

m

a
com

t
1- Return line, blue or with blue marking

ion in
r
te o

2- Supply line, black

thi
s
iva

do
3- Fuel line to metering pump - V54-
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

3.2 Removing and installing fuel delivery

unit, fuel gauge sender
⇒ “3.2.1 Removing and installing fuel delivery unit, front-wheel
drive”, page 43
⇒ “3.2.2 Removing and installing fuel delivery unit, four-wheel
drive”, page 46

3.2.1 Removing and installing fuel delivery

unit, front-wheel drive
Special tools and workshop equipment required

3. Fuel delivery unit, fuel gauge sender 43

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

♦ Key for union nut - 3217-

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
♦ Torque wrench (40 … 200 Nm) - V.A.G 1332-

ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

i
Removing

on
c

in t
or

• The fuel tank must not be more than 3/4 full.

his
ate

do
priv

c
• If necessary, drain fuel tank using fuel extractor - VAS 5190-
um
for

en
g

⇒ page 20 .
n

t.
yi Co
Cop py
– Disconnect earth cable at battery with ignition switched off ⇒
t. rig
gh ht
yri
Rep. gr. 27 ; Disconnecting and connecting battery . p by
co Vo
by lksw
cted agen
– Remove fuel tank ⇒ page 31 . Prote AG.

WARNING

♦ The fuel and the fuel lines in the fuel system can become
very hot (danger of scalding)!
♦ The fuel system is also under pressure! Before opening
the system, place a cloth around the connection and re‐
duce pressure by carefully loosening the connection!
♦ Wear eye and hand protection when performing any type
of repair work on the fuel system!

– Release connector -arrow- and pull off from flange -1-.

44 Rep. gr.20 - Fuel supply system

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

– Remove fuel lines -1- and -2-

⇒ “4.1 Separating plug-in connectors”, page 52 .
– On vehicles with auxiliary heater, remove fuel lines -3-
⇒ “4.1 Separating plug-in connectors”, page 52 .

– Unscrew union nut -1- using union nut tool - 3217- .

– Pull fuel delivery unit and seal out of the opening in fuel tank.

Note

♦ The lint-free cloth can be ordered from the ⇒ ServiceNet;

Workshop Equipment; Techno equipment catalogue; BMK
consumables .
♦ Whenever work is done on the fuel system, ensure cleanliness
and do the work carefully. The fuel system reacts sensitively
to the ingress of dirt.

– If the fuel delivery unit needs to be exchanged, check the in‐

side of the fuel tank AG. Volkswagen AG d
swafor
gen contaminants/soiling
oes and, if necessary,
clean with abylint-free
Vol
k
cloth. not
gu
d ara
se n
– If fuel tdelivery
ho
ri unit is to be renewed, old delivery unit
tee must be
or
drained
s au before disposal. ac
s
ce
le

Installing
un

pt
an
d
itte

y li

Install in reverse order of removal. During this procedure, observe

erm

ab

the following:
ility
ot p

wit

♦ When inserting the fuel delivery unit, ensure that the fuel
is n

h re

gauge sender - G- is not bent.

ole,

spec
urposes, in part or in wh

♦ Renew seal.
t to the co

♦ Insert seal for fuel delivery unit dry into opening of fuel tank.
♦ Moisten seal with fuel only when installing fuel delivery unit.
rrectne

♦ Do not interchange supply line and return line (return line blue
or with blue marking, supply line black).
ss o
cial p

♦ Ensure that line connections are tight.

inform
mer

♦ After installing fuel delivery unit, check that the supply, return
atio

and breather lines are still clipped onto the fuel tank.
om

n
c

i
or

– Push sealing flange downwards against spring force and bring

thi
te

sd

sealing flange into installation position.

iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

3. Fuel delivery unit, fuel gauge sender 45

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

Mark on flange -1- must align with mark on fuel tank -arrow-.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
– Tighten union nut -1-. orise nte
h eo
ut ra
– After installing fuel delivery
ss a unit, check that supply and return c
lines are still clipped onto fuel tank.

ce
e
nl

pt
du

an
– Observe installation position of fuel supply line to supplemen‐
itte

y li
tary heater ⇒ Auxiliary heater, supplementary heater; Rep.
erm

ab
ility
gr. 82 ; Fuel supply system .
ot p

wit
, is n

Specified torques

h re
hole

spec
♦ ⇒ “2.1 Assembly overview - fuel tank”, page 14
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

3.2.2 Removing and installing fuel delivery

his
ate

do
riv

unit, four-wheel drive

p

cum
for

en
ng

t.
Special tools and workshop equipment required
yi Co
Cop py
t. rig
♦ Special wrench - T10202-
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

46 Rep. gr.20 - Fuel supply system

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

♦ Torque wrench - V.A.G 1332-

Removing:
– Remove fuel tank ⇒ page 31 . AG. Volkswagen AG d
agen oes
olksw not
– Open locking ring using wrench - T10202- d by .
V gu
ara
ise nte
or eo
h
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
– Lift up fuel delivery unit slightly and pull off suction-jet pump

rrectness of i
fuel hoses -arrows-.
l purpos

– Withdraw oil seal and delivery unit from opening in fuel tank.
Installing:

nform
ercia

Install in reverse order of removal. The following should be ob‐

m

at
om

i
served:
on
c

in t
or

his
ate

do
riv

Note
p

cum
for

en
ng

t.
yi
♦ Do not bend fuel gauge sender when installing.
Co
Cop py
t. rig
gh
♦ Insert seal for flange or fuel delivery unit dry into opening of
ht
pyri by
Vo
fuel tank.
o
by c lksw
cted agen
Prote AG.
♦ Moisten seal with fuel only when installing flange or fuel de‐
livery unit.
♦ Ensure fuel hoses are seated correctly.
♦ Observe fitting position of fuel pump unit ⇒ page 19 .

3. Fuel delivery unit, fuel gauge sender 47

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

– Tighten locking ring using wrench - T10202- .

– Install fuel tank ⇒ page 31 .
Specified torques
♦ ⇒ “2.1 Assembly overview - fuel tank”, page 14

3.3 Removing and installing fuel gauge

sender - G-
⇒ “3.3.1 Removing and installing fuel gauge sender G , front-
wheel drive”, page 48
⇒ “3.3.2 Removing and installing fuel gauge sender G , four-wheel
drive”, page 49
⇒ “3.3.3 Removing and installing fuel gauge sender 2 G169 with
suction-jet pump, four-wheel drive”, page 50

3.3.1 Removing and installing fuel gauge

sender - G- , front-wheel driveswagen AG. Volkswagen AG does
olk not
yV gu
edb ara
ris nte
Note au
tho eo
ra
ss c

ce
e

♦ Gradual introduction of fuel delivery units with modified fuel

nl

pt
du

gauge senders - G- .
an
itte

y li
erm

♦ Removing (old version) ⇒ page 48 ab

ility
ot p

wit
♦ Removing (new version) ⇒ page 48
, is n

h re
hole

spec

Removing (old version):

es, in part or in w

t to the co

– Remove fuel delivery unit ⇒ page 43 .

– Release connectors -arrows- and pull off electrical lines -1-,
rrectness of i

-2- and -3-.

l purpos

– Lift securing tabs -4- and -5- using a screwdriver, and pull off
fuel gauge sender - G- downwards -arrow-.
nform
ercia

Installing
m

at

Install in reverse order of removal. During this procedure, observe

om

io

the following:
n
c

in t
or

his
e

– Insert fuel gauge sender - G- into guides on fuel delivery unit

at

do
riv

and press upwards until it engages.

p

cum
for

en
g

– Connect connector and ensure secure engagement.

n

t.
yi Co
op py
– Install fuel delivery unit ⇒ page 43 .
t. C rig
gh ht
pyri by
Vo
o
Removing (new version): by c lksw
cted agen
Prote AG.
– Remove fuel delivery unit ⇒ page 43 .

48 Rep. gr.20 - Fuel supply system

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

– Pull fuel gauge sender - G- slightly to side and upwards at the

same time.

– If the sender cannot be released in this way, the securing tabs

-arrows- must also be pushed to the side slightly.
– Note colour assignment of cables for re-installation.

– Release and pull off electrical connectors -1…3-. Then bend

back locking lugs of connectors.
Installing

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit

– Connect connectors -1…3-. Note colour assignment.

, is n

h re
hole

– Check connectors are secured properly by pulling.

spec
es, in part or in w

– Insert fuel gauge sender - G- into guide on fuel delivery unit

t to the co

and press down until it engages.

– Install fuel delivery unit ⇒ page 43 .
rrectness of i

Specified torques
l purpos

♦ ⇒ “2.1 Assembly overview - fuel tank”, page 14

nform
mercia

a
com

tion in
r
te o

3.3.2 Removing and installing fuel gauge

thi
s
iva

do

sender - G- , four-wheel drive

r
rp

cum
fo

en
ng

Removing:
t.
yi Co
Cop py
. rig
– Remove fuel delivery unit ⇒ page 46 .
t
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

3. Fuel delivery unit, fuel gauge sender 49

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

– Unplug connector -1-.

– Unclip fuel gauge sender - G- -2- upwards.
AG. Volkswagen AG d
Installing agen oes
olksw not
byV gu
ara
d
– Insert fuel gauge sender - G- into orisguides on fuel delivery unit
e nte
and press down until it engages.
aut
h eo
ra
ss c
– Fit connector.

ce
e
nl

pt
du

an
itte

y li
erm

ab
Note

ility
ot p

wit
, is n

All cable ties must be secured again in the same position on in‐

h re
hole

stallation.

spec
es, in part or in w

t to the co
– Install fuel delivery unit ⇒ page 46 .
Specified torques

rrectness of i
♦ ⇒ “2.1 Assembly overview - fuel tank”, page 14
l purpos

3.3.3 Removing and installing fuel gauge

nf
ercia

sender 2 - G169- with suction-jet pump,

orm
m

four-wheel drive

atio
om

n in
or c

Special tools and workshop equipment required

thi
te

sd
iva

♦ Special wrench - T10202-

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

♦ Torque wrench - V.A.G 1332-

Removing:
– Remove fuel tank ⇒ page 31 .
– Remove fuel delivery unit ⇒ page 46 .
– Open locking ring for fuel gauge sender 2 - G169- with wrench
- T10202- .

50 Rep. gr.20 - Fuel supply system

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

– Pull seal and fuel gauge sender 2 - G169- with suction-jet

pump out of opening in fuel tank. Unclip locking lugs
-arrows- of suction-jet pump.
AG. Volkswagen AG d
Installing: agen oes
olksw not
byV gu
ara
Install in reverse order of removal. The following should ris be ob‐
ed
nte
served: aut
ho eo
ra
ss c

ce
le
un

pt
Note

an
d
itte

y li
rm

ab
pe
♦ Do not bend fuel gauge sender when installing.

ility
ot

wit
, is n
♦ Insert seal for flange or fuel delivery unit dry into opening of

h re
fuel tank. hole

spec
es, in part or in w

♦ Moisten seal with fuel only when installing flange or fuel de‐

t to the co
livery unit.
♦ Ensure fuel hoses are seated correctly.

rrectness of i
♦ Observe fitting position of fuel pump unit ⇒ page 19 .
l purpos

– Install fuel delivery unit ⇒ page 46 .

nform
ercia

– Install fuel tank ⇒ page 31 .

m

a
com

t
Specified torques

ion in
r
te o

♦ ⇒ “2.1 Assembly overview - fuel tank”, page 14

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

3. Fuel delivery unit, fuel gauge sender 51

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

4 Plug-in connectors
⇒ “4.1 Separating plug-in connectors”, page 52

4.1 Separating plug-in connectors

Special tools and workshop equipment required
♦ Lever - T10468-

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
Assignment of plug-in connectors ss
a ac

ce
e
nl

pt
du

an
itte

Note

y li
erm

ab
ility
ot p

♦ The plug-in connectors for fuel, vacuum and breather lines are

wit
, is n

colour coded. There is either a coloured dot on the plug-in

h re
hole

connector or the release button is coloured.

spec
es, in part or in w

♦ Plug-in connectors for fuel lines must engage »audibly« when

t to the co
joined.
♦ Ensure plug-in connector is secured properly by pulling it.

rrectness of i
Colour assignment
l purpos

Plug-in connector Colour code on plug-in connector

nform
ercia

Fuel supply black

m

at
om

Fuel return line blue

ion
c

in t
r

Breather White, beige

o

his
ate

Vacuum green
do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
yri by
WARNING cop Vo
by lksw
cted agen
Prote AG.
The fuel line is under pressure.
Fuel poses danger of injury to eyes and skin.
Wear protective goggles and protective clothing to avoid injury
and contact with the skin. Wrap a cloth around the connection
before loosening hose connections. Then reduce pressure by
carefully opening the connection.

52 Rep. gr.20 - Fuel supply system

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

Version 1
Plug-in connector with release buttons -arrows- on right and left

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
ut
Open ss a ra
c

ce
le
Counterhold at the coupling point for fuel -1- in the engine com‐

un

pt
an
d
partment. itte

y li
rm

ab
– Insert lever - T10468- between heat shield and stop -arrow- of
pe

ility
fuel line -2- and counterhold.
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
Continued for all coupling points in fuel system:
r
rp

cum
fo

en
g

– Push plug-in connector -1- in -direction of arrow A-.

n

t.
yi Co
Cop py
– Press and hold release buttons.
t. rig
gh ht
pyri by
Vo
o
– Pull plug-in connector -1- off fuel line -2- in by c lksw
cted agen
-direction of arrow B-.
Prote AG.

Take note of colour assignment when installing. ⇒ page 52

Plug-in connectors for fuel lines must engage »audibly« when
joined.
– Ensure plug-in connector is secured properly by pulling it.

4. Plug-in connectors 53
 n AG. Volkswagen AG do
wage es n
Caddy 2016 ➤ yV
olks ot g
b ua
Fuel supply
ir se system - Diesel engines - Edition 04.2019
d ran
tee
tho
u or
a ac
Version 2 ss

ce
le
un

pt
Plug-in connector with pull-release mechanism -arrow-.

an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectnes
Open

s o
cial p

f in
– Push plug-in connector -1- in -direction of arrow A-.

form
mer

– Pull pull-release mechanism -2- in -direction of arrow B-.

atio
om

n
c

– Pull plug-in connector -1- off fuel line -3- in

i
or

n thi
e

-direction of arrow B-.

t

sd
iva

o
pr

c
Note colour assignment during installation ⇒ page 52 .

um
r
fo

en
ng

t.
yi
Plug-in connectors for fuel lines must engage »audibly« when
Co
op py
joined. t. C rig
gh ht
pyri by
– Ensure plug-in connector is secured properly by pulling it.
co Vo
by lksw
cted agen
Prote AG.

Version 3
Plug-in connector with button in front -arrow-
Open
– Press release button -arrow- and pull off plug-in connectors.
Note colour assignment during installation ⇒ page 52 .
Plug-in connectors for fuel lines must engage »audibly« when
joined.
– Ensure plug-in connector is secured properly by pulling it.

Version 4
Plug-in connector with release button -arrows- on right and left:
Open
– Push plug-in connector in -direction of arrow A-.
– Press release buttons -arrows- and pull off plug-in connector.
Note colour assignment during installation ⇒ page 52 .
Plug-in connectors for fuel lines must engage »audibly« when
joined.
– Ensure plug-in connector is secured properly by pulling it.

54 Rep. gr.20 - Fuel supply system

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

Version 5
Plug-in connector with release buttons -arrows- on right and left:
Open
– Press release buttons -arrows- and pull off plug-in connector.
Note colour assignment during installation ⇒ page 52 .
Plug-in connectors for fuel lines must engage »audibly« when
joined.
– Ensure plug-in connector is secured properly by pulling it.

Version 6
Plug-in connector with release buttons -arrows- on right and left:
AG. Volkswagen AG d
Open agen oes
olksw not
V gu
by ara
– Push plug-in connector -1- inris-direction
ed of arrow-, and hold it nte
in that position. ut
ho eo
ra
s a c
s
– Press release buttons -arrows- and pull off plug-in connector.

ce
le
un

pt
an
d

Note colour assignment during installation ⇒ page 52 .

itte

y li
rm

ab
Plug-in connectors for fuel lines must engage »audibly« when
pe

ility
joined.
ot

wit
, is n

h re
– Ensure plug-in connector is secured properly by pulling it.
hole

spec
es, in part or in w

t to the co
Version 7
Plug-in connector -1- with release buttons -2- on right and left:

rrectness of i
Open
l purpos

– Push plug-in connector -1- in -direction of arrow A-, and hold

it in that position. nform
ercia

– Press release button -2- in -direction of arrow B- and pull off

plug-in connector -1-.
m

a
com

tio

Note colour assignment during installation ⇒ page 52 .

n in
r
te o

thi

Plug-in connectors for fuel lines must engage »audibly« when

s
iva

do

joined.
r
rp

cum
fo

en
g

– Ensure plug-in connector is secured properly by pulling it.

n

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

4. Plug-in connectors 55
 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

5 Fuel filter
⇒ “5.1 Assembly overview - fuel filter”, page 56
⇒ “5.2 Removing and installing fuel filter”, page 58
⇒ “5.3 Removing and installing upper part of fuel filter”,
page 62
⇒ “5.4 Checking fuel filter”, page 65

⇒ “5.5 Removing and renewing fuel hoses in engine compart‐

ment, fuel filter with 3 connections”, page 67

5.1 Assembly overview - fuel filter

⇒ “5.1.1 Assembly overview - fuel filter with 4 connections”, page
56
⇒ “5.1.2 Assembly overview - fuel filter with 3 connections”, page
57

5.1.1 Assembly overview - fuel filter with 4 connections

1 - Fuel line agen

AG. Volkswagen AG d
oes
olksw not
V gu
2 - Bolts ed by ara
nte
ris
❑ Qty. 5 ut
ho eo
ra
a c
❑ Version A: 8 Nm ss

ce
le
un

❑ Version B: 5 Nm

pt
an
d
itte

y li
3 - Washer
erm

ab
ility
ot p

4 - Fuel line

wit
is n

h re
5 - Fuel line
ole,

spec
urposes, in part or in wh

6 - Fuel line

t to the co
7 - Fuel filter
❑ Upper part

rrectne
❑ Connection overview,
version A ⇒ page 57
❑ Connection overview, ss o
cial p

f
version B ⇒ page 57
inform
mer

❑ Removing and installing

atio

⇒ page 62
om

n
c

i
or

8 - Filter element
thi
te

sd
va

9 - Fuel filter
i

o
pr

cum
r
fo

❑ Lower part
en
ng

t.
yi Co
op
10 - Bolt/nut
C py
t. rig
gh ht
yri
❑ 10 Nm p by
o Vo
by c lksw
cted agen
11 - Seal Prote AG.

❑ Renew after removal

56 Rep. gr.20 - Fuel supply system

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

Fuel filter upper part, type A

Direction of fuel flow -arrows-
1 - Bolts
2 - Water drain plug, depending on equipment.
3 - Fuel supply line from fuel tank, white or white marking. Check
for secure seating.
4 - Fuel return line to fuel tank, blue or blue marking. Check for
secure seating.
5 - Fuel supply line to engine, white or white marking. Check for
secure seating.
6 - Fuel return line from engine, blue or blue marking. Check for
secure seating.

Fuel filter upper part, type B

Direction of fuel flow -arrows-
1 - Bolts
2 - Fuel return line to fuel tank, blue or blue marking. Check for
secure seating.
3 - Fuel supply line from fuel tank, white or white marking. Check
for secure seating.
4 - Fuel return line from engine, blue or blue marking. Check for
secure seating.
5 - Fuel supply line to engine, white or white marking. Check for
secure seating.

5.1.2 Assembly overview - fuel filter with 3 connections

G. Volkswage A n AG d
agen oes
olksw not
yV gu
db ara
rise nte
tho eo
s au ra
c
s
ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

5. Fuel filter 57
 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

1 - Fuel filter
❑ Lower part
❑ Removing and installing
⇒ page 60
2 - Filter element
3 - Fuel filter
❑ Upper part
❑ Removing and installing
⇒ page 62
4 - Bolts
❑ Qty. 5
❑ 5 Nm
5 - Drain valve
❑ Depending on equip‐
ment
AG. Volkswagen AG d
6 - Clamps agen oes
olksw not
yV gu
❑ Qty. 3 ised b ara
nte
or eo
h
7 - Fuel supply hose s aut ra
c
s
❑ To high-pressure pump

ce
le
un

pt
an
d

8 - Fuel return hose

itte

y li
erm

ab
❑ From engine

ility
ot p

wit
9 - Fuel supply hose
is n

h re
ole,

❑ From fuel tank

spec
urposes, in part or in wh

10 - Fuel return hose

t to the co
❑ From high-pressure
pump to fuel tank.

rrectne
11 - Bolts
❑ Qty. 2

ss o
❑ 8 Nm
cial p

f inform
12 - Nut
mer

atio
❑ 8 Nm
om

n
c

i
or

n thi
te

sd
iva

5.2 Removing and installing fuel filter

pr

cum
r
fo

en
ng

t.
yi
⇒ “5.2.1 Removing and installing fuel filter - fuel filter with 4 con‐
Co
op py
nections”, page 58
. C rig
ht ht
rig by
py
⇒ “5.2.2 Removing and installing fuel filter - fuel filter with 3 con‐
co Vo
by lksw
cted
nections”, page 60
agen
Prote AG.

5.2.1 Removing and installing fuel filter - fuel

filter with 4 connections
Special tools and workshop equipment required

58 Rep. gr.20 - Fuel supply system

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

♦ Torque wrench - V.A.G 1410-

♦ Spring-type clip pliers - VAS 6362-

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

Removing

wit
, is n

h re
hole

WARNING

spec
es, in part or in w

t to the co
The fuel line is under pressure.
Fuel poses danger of injury to eyes and skin.

rrectness of i
Wear protective goggles and protective clothing to avoid injury
l purpos

and contact with the skin. Wrap a cloth around the connection
before loosening hose connections. Then reduce pressure by
carefully opening the connection.
nf
ercia

orm
m

atio
m

– Open plug-in connectors -A- and -B- of fuel supply lines.

o

n in
or c

thi

– Collect escaping fuel with a cleaning cloth.

te

sd
iva

o
r
rp

cu
o

– Disconnect electrical connector -1- at fuel temperature sender

f

en
ng

t.
- G81- .
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
Note
by lksw
cted agen
Prote AG.

Ignore position -3-.

– Open clamps -2- and -4-.

– Open retainer -arrow-.
– Pull off fuel hoses.
– Collect escaping fuel with a cleaning cloth.

5. Fuel filter 59
 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

– Unclip bracket for coolant hose -1-.

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
or
– Loosen bolt -1-. au ac
ss

ce
le
un

pt
an
d

Note
itte

y li
erm

ab
ility
ot p

Disregard items -4, 5 and 6-.

wit
is n

h re
ole,

– Unscrew bolt -2-.

spec
urposes, in part or in wh

– Unscrew nut -3-.

t to the co
– Remove fuel filter -7- with fuel hoses.

rrectne
Installing
Install in reverse order of removal, observing the following:

ss o
♦ Rout fuel hoses free of kinks.
cial p

f inform
♦ Ensure fuel hoses are seated correctly.
mer

atio
m

♦ Do not interchange fuel supply and return lines (return line is

o

n
c

blue or with blue markings and supply line is white or with white i
or

n thi
e

markings).
t

sd
iva

o
pr

♦ Clip fuel and coolant hoses into retainers again.

um
r
fo

en
ng

t.
yi
– Fill/bleed fuel system ⇒ Rep. gr. 23 ; Injection system; Filling/
Co
op py
bleeding fuel system . t. C rig
gh ht
pyri by
Specified torques
co Vo
by lksw
cted agen
Prote AG.
♦ ⇒ “5.1.1 Assembly overview - fuel filter with 4 connections”,
page 56

5.2.2 Removing and installing fuel filter - fuel

filter with 3 connections
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1410-

60 Rep. gr.20 - Fuel supply system

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

♦ Hose clamp pliers - V.A.G 1921-

Removing
– Open retainer -arrow-.
– Unclip fuel lines -1-.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

5. Fuel filter 61
 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

– Unscrew bolts -2-.

– Unscrew nut -1-. wage
n AG. Volkswagen AG do
es n
olks ot g
byV ua
d ran
WARNING ir se tee
tho
u or
a ac
ss
The fuel line is under pressure.

ce
e
nl

pt
du

an
Fuel poses danger of injury to eyes and skin.
itte

y li
erm

ab
Wear protective goggles and protective clothing to avoid injury

ility
ot p

and contact with the skin. Wrap a cloth around the connection

wit
, is n

before loosening hose connections. Then reduce pressure by

h re
hole

carefully opening the connection.

spec
es, in part or in w

t to the co
– Loosen clamps -3, 4 and 5-.
– Collect escaping fuel with a cleaning cloth.

rrectness of i
– Pull off fuel hoses.
l purpos

– Remove fuel filter.

nform
ercia

Installing
m

at
Install in reverse order of removal, observing the following:
om

ion
c

in t
r

♦ Rout fuel hoses free of kinks.

o

his
ate

do
riv

♦ Ensure fuel hoses are seated correctly.

p

cum
for

en
g

♦ Do not interchange fuel supply and return lines (return line is

n

t.
yi Co
blue or with blue markings and supply line is white or with white Cop py
. rig
markings).
t
gh ht
pyri by
Vo
co
♦ Clip fuel and coolant hoses into retainers again.
by lksw
cted agen
Prote AG.
– Fill/bleed fuel system ⇒ Rep. gr. 23 ; Injection system; Filling/
bleeding fuel system .
Specified torques
♦ ⇒ “5.1.2 Assembly overview - fuel filter with 3 connections”,
page 57

5.3 Removing and installing upper part of

fuel filter
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1410-

62 Rep. gr.20 - Fuel supply system

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

♦ Diesel extractor - VAS 5226-

♦ Angled screwdriver - VAS 6543-

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
s c
Removing s
ce
le
un

pt
an
d
itte

y li

WARNING
rm

ab
pe

ility
ot

The fuel line is under pressure.

wit
, is n

h re

Fuel poses danger of injury to eyes and skin.

hole

spec
es, in part or in w

Wear protective goggles and protective clothing to avoid injury

t to the co

and contact with the skin. Wrap a cloth around the connection
before loosening hose connections. Then reduce pressure by
carefully opening the connection.
rrectness of i
l purpos

Caution
nform
ercia

♦ Do not pull fuel hoses off fuel filter cover and do not apply
m

a
com

leverage at unions. Levering/pulling leads to leaks and

ion in

damage to the upper part of the fuel filter.

r
te o

thi
s
iva

♦ Ensure that no diesel fuel contacts other components in

do
r
rp

the engine compartment. Clean immediately, if necessa‐

um
fo

ry.
en
ng

t.
yi Co
Cop py
t. rig
gh ht
yri by
– Unscrew bolts -arrows-.
op Vo
by c lksw
cted agen
Prote AG.
– Detach upper part of fuel filter.

5. Fuel filter 63
 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

If upper part of fuel filter is tight or seized

– Insert angled screwdriver - VAS 6543- into assembly groove
-arrow A-.
– Raise fuel filter upper part at assembly groove -arrow A- using
angled screwdriver - VAS 6543- .

– Remove seal -2- from upper part of fuel tank -1-. To do this,
insert screwdriver in prescribed groove -arrow- and lever out
seal -2-.
– Loosen clamps.
– Pull off fuel hoses.
– Detach upper part of fuel filter.

AG. Volkswagen AG d
agen oes
olksw not
V gu
by ara
Installing rised
nte
ho eo
ut
Install in reverse order of removal, observing thess following:
a ra
c
ce
le

– Moisten new seal -1- lightly with diesel fuel, and insert fuel filter
un

pt
an
d

upper part -arrows-.

itte

y li
rm

ab

– Place upper part of fuel filter with seal properly onto lower part
pe

ility

of fuel filter, and press on firmly and evenly until the upper part
ot

wit
, is n

of fuel filter is completely seated.

h re
hole

spec
es, in part or in w

t to the co
rrectness of i

– Tighten bolts -arrows- hand-tight.

l purpos

Caution
nform
ercia

Do NOT tighten the bolts for the upper part of the fuel filter until
m

it is fully in contact with the lower part.

com

tion in
r
te o

thi
s
iva

do

– Then, tighten bolts -arrows- in prescribed sequence to speci‐

r
rp

cum

fied torque.
fo

en
ng

t.
yi Co
– Bleed fuel system ⇒ Rep. gr. 24 ; Injection system; Filling/ Cop py
bleeding fuel system .
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

64 Rep. gr.20 - Fuel supply system

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

5.4 Checking fuel filter

Special tools and workshop equipment required
♦ Pressure gauge - VAS 6551-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
Test conditions
• Fuses must be OK.

rrectne
• Battery voltage at least 12 V

s
• Ignition off

s o
cial p

f i
• There must be at least 10 l of fuel in the fuel tank.

nform
mer

• All electrical consumers, e.g. lights and rear window heating,

atio
m

must be switched off.

o

n
c

i
or

n thi
Sequence of operations
te

sd
iva

o
pr

cum
r
fo

WARNING

en
ng

t.
yi Co
Cop py
t.
♦ Fuel supply line is pressurised. Wear protective goggles
rig
gh ht
yri by
and protective clothing to avoid injury and contact with the cop Vo
by lksw
skin. Wrap a cloth around the connection before loosening cted agen
Prote AG.
hose connections. Then release pressure by carefully
pulling hose off connection.
♦ Read through the rules for cleanliness and the instructions
for working on the fuel system.
♦ Always follow these rules for cleanliness and instructions
before starting work and while working on the fuel system.
♦ Wrap a clean cloth around the connection before opening
the fuel system, then carefully loosen the connection to
release the pressure.

– Remove fuel supply line to engine on fuel filter ⇒ page 56 .

– Collect escaping fuel with a cleaning cloth.

5. Fuel filter 65
 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

– Attach connection -A- of pressure tester - VAS 6551- to open

end of fuel filter using suitable line from pressure tester - VAS
6551- .
– Attach connection -B- of pressure tester - VAS 6551- to open
line of high-pressure pump using suitable line from pressure
tester - VAS 6551- .
– Switch on pressure tester - VAS 6551- .
– Close shut-off tap -C- of pressure tester - VAS 6551- .
– Carefully open shut-off valves -A- and -B-.
– Start engine.
• Read pressure indicated on pressure tester - VAS 6551- ;
specification: at least 0.5 bar for fuel filter with 4 connections
(0.5-bar low pressure fuel system)
• Read pressure indicated on pressure tester - VAS 6551- ;
specification: at least 4.5 bar for fuel filter with 3 connections
(6.0-bar low pressure fuel system)
If the specified value is attained, the fuel system is OK.
If specification is not obtained
– Reconnect fuel supply line to engine on fuel filter.
– Remove fuel supply line from fuelgetank on
n AG. V fuel filter does
olkswagen AG
swa
⇒ page 56 . yV
olk not
gu b ara
ed nte
– Collect escaping fuel
tho
riswith a cleaning cloth. e or
au ac
ss
– Attach connection -A- of pressure tester - VAS 6551- to open
ce
le
un

pt

end of fuel filter using suitable line from pressure tester - VAS
an
d
itte

6551- .
y li
erm

ab
ility

– Attach connection -B- of pressure tester - VAS 6551- to open

ot p

wit

line of fuel tank using suitable line from pressure tester - VAS
is n

h re

6551- .
ole,

spec
urposes, in part or in wh

– Switch on pressure tester - VAS 6551- .

t to the co

– Close shut-off tap -C- of pressure tester - VAS 6551- .

– Carefully open shut-off valves -A- and -B-.
rrectne

– Start engine.
ss

• Read pressure indicated on pressure tester - VAS 6551- ;

o
cial p

specification: at least 0.5 bar for fuel filter with 4 connections

inform

(0.5-bar low pressure fuel system)

mer

atio

• Read pressure indicated on pressure tester - VAS 6551- ;

om

specification: at least 4.5 bar for fuel filter with 3 connections

c

i
or

(6.0-bar low pressure fuel system)

thi
te

sd
iva

o
r

If reading matches specification:

p

cum
r
fo

en
ng

– Renew fuel filter.

t.
yi Co
Cop py
t.
If specification is not obtained
rig
gh ht
pyri by
Vo
o
by c
– Check fuel system pressurisation pump - G6- ⇒ page 72 .
lksw
cted agen
Prote AG.

66 Rep. gr.20 - Fuel supply system

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

5.5 Removing and renewing fuel hoses in

engine compartment, fuel filter with 3
connections

Note

♦ On this engine, some of the connections for the pressurised

fuel hoses have what is known as a 2 wave profile section
-arrows- with an engagement lip. This reduces the likelihood
of fuel system leaks.
♦ When the fuel hoses are removed, the very thin sealing layer
on the inside of the fuel hoses is damaged.
♦ This damage cannot be detected with the naked eye. After
some time, it leads to leaks in the fuel system.
♦ If the fuel filter only has to be removed to gain space, leave
the fuel hoses on the fuel filter and high-pressure pump. Place
the fuel filter with the hoses connected on the engine to avoid
having to renew them unnecessarily.

AG. Volkswagen AG d
agen Caution oes
olksw not
byV gu
ara
ed
is nte
• After removinguththe
o fuel hoses from the connections with
r eo
wave profilesssection and engagement lip, these fuel hoses
a ra
c
have to be replaced.
ce
le
un

pt
an
d
itte

y li
erm

ab

♦ Wave profile section -arrows- and engagement lip

ility
ot p

wit

♦ Upper part of fuel filter

is n

h re
ole,

♦ Fuel temperature sender - G81-

spec
urposes, in part or in wh

t to the co

Note
rrectne

♦ If other components are just removed, check whether it is real‐

ly necessary to disconnect the fuel system from components
with wave section and engagement lip.
ss o
cial p

♦ Use other fuel system connection points in the engine com‐

inform

partment.
mer

atio
om

If a fuel hose cannot be removed from the connections by hand:

c

i
or

n thi
te

sd
iva

o
r

Caution
p

cum
r
fo

en
ng

t.
yi
Never insert a screwdriver or similar tool between the hose and
Co
Cop py
the connection! ht. rig
rig ht
py by
o Vo
♦ Risk of damage to the connection - component must be by c lksw
cted agen
renewed.
Prote AG.

– Turn fuel hose with suitable pliers and pull off hose.
If fuel hose still cannot be removed from the connection:
– Cut only into the textile layer of the fuel hose lengthways and
pull hose off.
• Do not cut the inner rubber layer. If the connection is damaged,
the entire component must be renewed.

5. Fuel filter 67
 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

Note

♦ Before attaching a new fuel hose, remove grease, oil and dirt
thoroughly from the hose connection. Do not use any metal
tools to do this as they could damage the hose connection.
♦ Attach fuel hose to connection without lubricant and then se‐
cure with spring-type clip.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

68 Rep. gr.20 - Fuel supply system

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

6 Accelerator pedal
⇒ “6.1 Assembly overview - accelerator module”, page 69
⇒ “6.2 Removing and installing accelerator module with acceler‐
ator position sender G79 / G185 ”, page 69

6.1 Assembly overview - accelerator module

1 - Connector
❑ Black, 6-pin.
2 - Gas pedal module - GX2-
❑ Includes
Acceleration pedal posi‐ agen
AG. Volkswagen AG d
oes
tion sender - G79- olksw not
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is nte
Accelerator position hor eo
ut
sender 2 - G185- ss a ra
c

ce
e

❑ To remove, release us‐

nl

pt
du

an
ing release tool -
itte

y li
T10238- or release tool
erm

ab
- T10240- .

ility
ot p

wit
, is n

-A- openings for release tool -

h re
T10238- .
hole

spec
es, in part or in w

❑ Removing and installing

t to the co
⇒ page 69
3 - Bolt

rrectness of i
❑ 10 Nm
l purpos

4 - Cover

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

6.2 Removing and installing accelerator

module with accelerator position sender
-G79- / -G185-
Special tools and workshop equipment required

6. Accelerator pedal 69
 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019
AG. Volkswagen AG d
♦ Release tool - T10238- agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
♦ Torque wrench - V.A.G 1331-

rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
For right-hand drive:
o Vo
by c lksw
cted agen
Prote AG.

♦ Release tool - T10240-

Removing:
– Prior to removing accelerator module, loosen plastic nuts
-arrows- to remove footwell cover.
– Lever out cover cap ⇒ Item 4 (page 69) with a screwdriver.
– Unscrew bolt ⇒ Item 3 (page 69) .

70 Rep. gr.20 - Fuel supply system

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

Releasing accelerator module:

– To remove accelerator module, push release tool - T10238-
(for right-hand drive vehicles release tool - T10240- ) into
intended openings to stop as shown.
– Disconnect the electrical plug connector and pull away the line
routing at the accelerator module.

Installing:
Install in reverse order of removal, observing the following:
– Connect line routing -1- and electrical connector -2- to accel‐
erator module.
– Push accelerator module onto securing bolts -6-.
– Insert centring pin -7- into bore.
– Secure accelerator module with bolt -3-. Fit cap -4-.

AG. Volkswagen AG d
agen oes
olksw not
V gu
by ara
– Install cover for steering column again. rised
nte
ho eo
ut
Specified torques ss a ra
c

ce
le

♦ ⇒ “6.1 Assembly overview - accelerator module”, page 69

un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

6. Accelerator pedal 71
 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

7 Fuel pump
⇒ “7.1 Checking fuel system pressurisation pump G6 ”,
page 72
⇒ “7.2 Supplementary fuel pump V393 ”, page 87

7.1 Checking fuel system pressurisation

pump - G6-
⇒ “7.1.1 Checking voltage supply and current draw of fuel system
pressurisation pump G6 ”, page 72
⇒ “7.1.2 Checking delivery pressure of fuel system pressurisation
pump G6 , engine codes CAYD, CAYE, CFHC, CFHF, CLCA”, AG. Volkswagen AG d
page 75 lksw
agen oes
n o ot g
yV ua
⇒ “7.1.3 Checking delivery pressure of fuelrisystem
se
db pressurisation ran
tee
pump G6 , engine codes CUUB, CUUC, thCUUD,
o CUUE, CUUF, or
DFSB, DFSC, DFSD, DFSE, DFSF”,sspage au 77 ac

ce
e
nl

⇒ “7.1.4 Checking delivery rate of fuel system pressurisation

pt
du

an
pump G6 , engine codes CAYD, CAYE, CFHC, CFHF, CLCA”,
itte

y li
page 82
erm

ab
ility
ot p

⇒ “7.1.5 Checking delivery rate of fuel pump , engine codes

wit
, is n

CUUB, CUUC, CUUD, CUUE, CUUF, DFSB, DFSC, DFSD,

h re
hole

DFSE, DFSF”, page 84

spec
es, in part or in w

7.1.1 Checking voltage supply and current

t to the co
draw of fuel system pressurisation pump
- G6-

rrectness of i
l purpos

Special tools and workshop equipment required

♦ Hand multimeter - V.A.G 1526 E-

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

♦ Pick-up clamp - V.A.G 1526B/2-

72 Rep. gr.20 - Fuel supply system

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

♦ Test instrument adapter/DSO (5-pin) - VAS 5565-

♦ Vehicle diagnostic tester

Test conditions agen
AG. Volkswagen AG d
oes
olksw not
• Fuses must be OK. d by V gu
ara
rise nte
• The battery voltage must be at least 12 V; if necessary
utho
connect eo
ra
a
a battery charger. ss c

ce
le
un

• All electrical consumers, e.g. lights and rear window heating,

pt
an
d
itte

must be switched off.

y li
erm

ab
Checking function and voltage supply

ility
ot p

wit
is n

– If fitted, disconnect electrical connector -A- to supplementary

h re
ole,

fuel pump - V393- .

spec
urposes, in part or in wh

– Raise vehicle on lift.

t to the co
Vehicles with front-wheel drive
– Have a second mechanic switch on ignition.

rrectne
• The fuel pump must be heard to run for about 2 seconds.

ss
Vehicles with all-wheel drive

o
cial p

f inform
– Carry out Guided Function Check electronic fuel pump
mer

(s) using ⇒ Vehicle diagnostic tester.

atio
om

n
c

• To check the voltage, the engine has to be started or the de‐

i
or

n thi
e

livery unit has to be actuated via the tester.

t

sd
iva

o
pr

cum
r
fo

Continued for all vehicles

en
ng

t.
yi Co
op
– If fuel pump does not start, lower fuel tank ⇒ page 31 .
C py
t. rig
gh ht
yri by
– Pull electrical connector -arrow- off flange -1-. cop Vo
by lksw
cted agen
Prote AG.

7. Fuel pump 73
 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

– Connect test instrument adapter/DSO (5-pin) - VAS 5565- be‐

tween electrical connector and flange.
– Connect hand-held multimeter - V.A.G 1526 E- to contacts
-1- and -5- of test instrument adapter/DSO (5-pin) - VAS
5565- .
– Carry out Guided Function Check electronic fuel pump
(s) using ⇒ Vehicle diagnostic tester.

• The fuel pump will be activated for 30 seconds.

G. Volkswage nA n AG d
wage oe
– Read off voltage value Voon
lks hand-held multimeter - V.A.G
s no
t gu 1526
by
E- . ise
d ara
n r tee
tho
• Specifications au= approx. battery voltage. or
ac
s

ce
If no voltage is present:
le
un

pt
an
d
itte

– Check activation of fuel pump relay and wiring for open circuit

y li
erm

ab
and short circuit ⇒ Vehicle diagnostic tester.

ility
ot p

wit
Voltage supply OK:
is n

h re
ole,

– Remove fuel delivery unit ⇒ page 43 .

spec
urposes, in part or in wh

– Check that the electrical lines between flange and fuel pump

t to the co
are connected and have continuity.
If no open circuit can be found:

rrectne
– Renew fuel delivery unit.
ss o
Checking current draw of fuel pump
cial p

f inform

Test conditions:
mer

atio
m

• Battery voltage at least 12 V

o

n
c

i
or

• Diesel fuel temperature above 10°C

thi
te

sd
iva

o
r

– Lower fuel tank ⇒ page 31 .

p

cum
r
fo

en
ng

– Pull electrical connector -arrow- off flange -1-.

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Connect test instrument adapter/DSO (5-pin) - VAS 5565- be‐

tween electrical connector and fuel delivery unit.
– Connect pick-up clamp -A- to red terminal with lettering “pick-
up clamp” on test instrument adapter/DSO (5-pin) - VAS
5565- .

74 Rep. gr.20 - Fuel supply system

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

– If fitted, disconnect electrical connector -A- to supplementary

fuel pump - V393- .
– Switch on ignition.
– Carry out Guided Function Check electronic fuel pump
(s) using ⇒ Vehicle diagnostic tester.

• The fuel pump will be activated for 30 seconds.

– Read current draw on hand-held multimeter - V.A.G 1526 E- .
• Specification: max. 7.5 amps. (for fuel filters with 4 connec‐
tions, 0.5-bar low pressure fuel system)
• Specification: 8.0 to 14.0 amps. (for fuel filters with 3 connec‐
tions, 6.0-bar low pressure fuel system)
If the measured value is not within specifications:
– Remove fuel delivery unit ⇒ page 43 .
– Check that the electrical lines between flange and fuel pump
are connected and have continuity.
If no open circuit can be found
– Renew fuel delivery unit ⇒ page 43 .

7.1.2 Checking delivery pressure of fuel sys‐

tem pressurisation pump - G6- , engine
codes CAYD, CAYE, CFHC, CFHF,
CLCA
AG. Volkswagen AG d
agen oes
Special tools and workshop equipment
Vol required
ksw not
gu
y
db ara
♦ Pressure tester (diesel) - VASrise 6551- nte
tho eo
au ra
c
ss
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i

♦ Vehicle diagnostic tester

l purpos

Test conditions
nform
ercia

• Room temperature or fuel temperature 10°C to 25°C.

m

at

• Fuses must be OK.

om

ion
c

in t
r

• Battery voltage at least 12 V

o

his
ate

do
riv

• All electrical consumers, e.g. lights and rear window heating,

p

cum
or

must be switched off.

f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

7. Fuel pump 75
 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

WARNING

The fuel line is under pressure.

Fuel poses danger of injury to eyes and skin.
Wear protective goggles and protective clothing to avoid injury
and contact with the skin. Wrap a cloth around the connection
before loosening hose connections. Then reduce pressure by
carefully opening the connection.
Bear in mind that the fuel pump can be activated due to open‐
ing of a door with the battery connected. Fuel can escape if the
system has been opened.

Sequence of operations
– Separate quick-release fastener -2- (black or with black mark‐
ing) of fuel supply line.
– Connect pressure tester (diesel) - VAS 6551- to open ends of
fuel supply line using suitable lines from adapter set - VAS
6551- .

– Switch on pressure tester (diesel) - VAS 6551- -1-.

– Open shut-off taps -A- and -B- on pressure tester (diesel) -
VAS 6551- -1-.
– Close shut-off valve -C-. agen
AG. Volkswagen AG d
oes
olksw not
– Start engine and run at b yV
idling speed. gu
ara
ed
ris nte
o eo
– Close shut-off tapaut -B- for 15 seconds max. During this time,
h
ra
read pressure indicated
ss on pressure tester (diesel) - VAS c
ce

6551- .
le
un

pt
an
d
itte

• Specification: at least 0.5 bar.

y li
erm

ab
ility

If delivery pressure temporarily drops:

ot p

wit
is n

– Renew fuel delivery unit ⇒ page 43 .

h re
ole,

spec

If specifications are met:

urposes, in part or in wh

t to the co

– In the event of engine running problems, renew fuel filter to

eliminate potential risk of fuel filter blockage ⇒ page 58 .
rrectne

If specifications are not met:

s

– Disconnect fuel supply line -1- on front right of fuel tank.

s o
cial p

f i

– Connect pressure tester (diesel) - VAS 6551- to open ends of

nform

fuel supply line using suitable lines from adapter set - VAS
mer

6551- .
atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

76 Rep. gr.20 - Fuel supply system

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

– Switch on pressure tester (diesel) - VAS 6551- .

– Open shut-off taps -A- and -B- of pressure tester.
– Close shut-off valve -C-.
– Start engine and run at idling speed.
– Close shut-off tap -B- for 15 seconds max. During this time,
read pressure indicated on pressure tester (diesel) - VAS
6551- .
• Specification: at least 0.5 bar.
olkswagen AG
en AG. V
If the specifications are
olksagain not attained:
wag does
not
byV gu
ara
– Check fuel pump
ris
ed
delivery rate ⇒ page 82 . nte
tho eo
au ra
ss c
7.1.3 Checking delivery pressure of fuel sys‐

ce
le
un

pt
tem pressurisation pump - G6- , engine

an
d
itte

y li
codes CUUB, CUUC, CUUD, CUUE,
rm

ab
pe

ility
CUUF, DFSB, DFSC, DFSD, DFSE,
ot

wit
, is n

h re
DFSF
hole

spec
es, in part or in w

Special tools and workshop equipment required

t to the co
♦ Pressure tester (diesel) - VAS 6551-

rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
♦ Vehicle diagnostic tester
t. rig
gh ht
pyri by
Vo
o
Test conditions
c by lksw
cted agen
Prote AG.
• Battery voltage at least 12.5 V
• Fuses OK.
• Fuel pump control unit - J538- OK.
• Fuel filter OK.
• Make sure vehicle is placed on a level surface
• Fuel tank at least 50% full
• All electrical consumers, e.g. lights and rear window heating,
must be switched off.
• Ignition off

7. Fuel pump 77
 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

Sequence of operations

WARNING

The fuel line is under pressure.

Fuel poses danger of injury to eyes and skin.
Wear protective goggles and protective clothing to avoid injury
and contact with the skin. Wrap a cloth around the connection
before loosening hose connections. Then reduce pressure by
carefully opening the connection.
Bear in mind that the fuel pump can be activated due to open‐
ing of a door with the battery connected. Fuel can escape if the
system has been opened.

– If fitted, remove engine cover panel ⇒ Rep. gr. 10 ; Engine

cover panel; Removing and installing engine cover panel .
– Loosen clamp -arrow-.
– Pull fuel supply line -1- off high-pressure pump -2-.

– Fit connection fitting - VAS 6551/5-1- into fuel supply line -1- ,
and secure it with clamp. AG. Volkswagen A gen G do
swa es
– Connect hose - VAS 6551/2- bbetween
yV
olk connecting nipple - VASnot
gu
6551/5-1- and connectionrispoint
ed -A- of pressure tester (diesel) arante
- VAS 6551- . ut
ho eo
r
sa ac
– Connect hose - VASs 6551/5-2- between connection -B- of
ce
le

pressure tester (diesel) - VAS 6551- and high-pressure pump

un

pt
an
d

-2-.
itte

y li
rm

ab

– Secure hose - VAS 6551/5-2- to high-pressure pump -2- with

pe

ility
ot

a clip.
wit
, is n

h re

– Switch on pressure tester (diesel) - VAS 6551- .

hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

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ng

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Cop py
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pyri by
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by c lksw
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Prote AG.

78 Rep. gr.20 - Fuel supply system

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

– Close shut-off valve -C-.

– Open shut-off taps -A- and -B- on pressure tester (diesel) -
VAS 6551- -1-.
– Connect ⇒ Vehicle diagnostic tester.
– Select Guided Function 01 Activate fuel pump .
– Select function Check fuel pump delivery pressure/de-
livery rate .

– Follow further instructions displayed on ⇒ Vehicle diagnostic

tester.

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Note yV
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The fuel pump is unow
tho
activated. or
a ac
ss

ce
le

– Read fuel pressure indicated on pressure tester (diesel) - VAS

un

pt
an
d

6551- .
itte

y li
rm

ab
• Specification: min. 4.5 bar
pe

ility
ot

wit
, is n

h re
If specification is not attained
hole

spec
– Check fuel lines in engine compartment for leaks.
es, in part or in w

t to the co
– Check fuel lines in engine compartment for leaks.
If no fault is detected

rrectness of i
– Check fuel pressure before fuel filter.
l purpos

Checking fuel pressure before fuel filter

nform
ercia

WARNING
m

a
com

tion in

The fuel line is under pressure.

r
te o

thi

Fuel poses danger of injury to eyes and skin.

s
iva

do
r
rp

cum

Wear protective goggles and protective clothing to avoid injury

fo

en
ng

and contact with the skin. Wrap a cloth around the connection
t.
yi Co
op
before loosening hose connections. Then reduce pressure by C py
t. rig
carefully opening the connection.
gh ht
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– Pull off fuel supply line -1-.

7. Fuel pump 79
 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

– Connect hose - VAS 6551/2- between fuel supply line from fuel
tank and connection -B- of pressure tester (diesel) - VAS
6551- .
– Connect hose - VAS 6551/1- between connection point -A- of
pressure tester (diesel) - VAS 6551- and fuel line -1- leading
to fuel filter.
– Switch on pressure tester (diesel) - VAS 6551- .

AG. Volkswagen AG d
agen oes
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y V gu
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– Close shut-off valve -C-. auth eo
ra
ss c
– Open shut-off taps -A- and -B- on pressure tester (diesel) -

ce
e
nl

pt
VAS 6551- -1-.
du

an
itte

y li
– Repeat function Check fuel pump delivery pressure/
erm

ab
ility
delivery rate using ⇒ Vehicle diagnostic tester.
ot p

wit
, is n

h re
If specification is now obtained
hole

spec
– Check fuel filter ⇒ page 65 .
es, in part or in w

t to the co
– If necessary, renew fuel filter.
If specification is not attained rrectness of i

Check fuel pressure on fuel delivery unit.

l purpos

Checking fuel pressure on fuel delivery unit

nf
ercia

– Reconnect plug-in connector to fuel filter.

rm
m

atio
m

– Lower fuel tank ⇒ page 31 .

o

n in
or c

– Check electrical connector -arrow- for firm seating.

thi
te

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Prote AG.

80 Rep. gr.20 - Fuel supply system

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

WARNING

The fuel line is under pressure.

Fuel poses danger of injury to eyes and skin.
Wear protective goggles and protective clothing to avoid injury
and contact with the skin. Wrap a cloth around the connection
gen AG
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does
swa
before loosening hose connections. Then reduce y V pressure by
olk not
gu
carefully opening the connection. ris
ed b ara
nt ee
tho or
s au ac
s
– Pull fuel supply line (black or black marking) -2- off fuel delivery

ce
le
un

pt
unit.

an
d
itte

y li
erm

ab
– Collect escaping fuel with a cleaning cloth.

ility
ot p

wit
is n

– Attach connection -A- of pressure tester (diesel) - VAS 6551-

h re
ole,

to open end of fuel delivery unit using suitable line from pres‐

spec
urposes, in part or in wh

sure tester (diesel) - VAS 6551- .

t to the co
– Close shut-off taps -B- and -C- on pressure tester (diesel) -
VAS 6551- .

rrectne
– Switch on pressure tester (diesel) - VAS 6551- .
– Connect ⇒ Vehicle diagnostic tester.

ss o
– Carry out guided function Checking electronic fuel pump
cial p

f in
(s) .

form
mer

atio
om

n
c

i
Note
or

n thi
te

sd
iva

o
The fuel pump will be activated for 30 seconds.
pr

cum
r
fo

en
ng

t.
yi Co
– Read pressure indicated on pressure tester (diesel) - VAS . Cop py
6551- .
ht rig
rig ht
py by
co Vo
• Specification: 7.2 ± 0.5 bar
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cted agen
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If specification is attained
– Check fuel lines to engine for damage.
– Check fuel lines for leaks.

7. Fuel pump 81
 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

If specification is not reached, or specified pressure drops com‐

pletely or temporarily, the following faults may be present
♦ Battery voltage below 12.5 V
♦ Delivery rate of fuel pump too low
♦ Voltage supply of fuel pump not OK
♦ Current draw of fuel pump too low
♦ Filter strainer of fuel delivery unit soiled
♦ Quick-release coupling in fuel delivery unit defective
♦ Check if all hoses -arrows- are connected
If no fault is detected

Note

If the filter strainer is not clogged/soiled, if all lines are connected

and the fuel pressure specification is still not attained, the fuel
delivery unit is defective.

– Renew fuel delivery unit ⇒ page 43 .

7.1.4 Checking delivery rate of fuel system

pressurisation pump - G6- , engine co‐
des CAYD, CAYE, CFHC, CFHF, CLCA
Special tools and workshop equipment required
♦ Pressure tester (diesel) - VAS 6551-

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ss
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nl

pt
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itte

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erm

ab
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ot p

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hole

spec
es, in part or in w

♦ Vehicle diagnostic tester

t to the co

♦ Measuring container, fuel-resistant

rrectness of i

Test conditions
• Fuses must be OK.
l purpos

• Battery voltage at least 12 V

nf
ercia

• All electrical consumers, e.g. lights and rear window heating,

rm
m

must be switched off.

atio
om

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or c

thi
te

sd
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rp

cu
o

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Cop py
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pyri by
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by
cted agen
Prote AG.

82 Rep. gr.20 - Fuel supply system

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

Sequence of operations
– If fitted, separate electrical connector -A- on supplementary
fuel pump - V393- .

WARNING

The fuel line is under pressure.

Fuel poses danger of injury to eyes and skin.
Wear protective goggles and protective clothing to avoid injury
and contact with the skin. Wrap a cloth around the connection
before loosening hose connections. Then reduce pressure by
carefully opening the connection.
Bear in mind that the fuel pump can be activated due to open‐
ing of a door with the battery connected. Fuel can escape if the
system has been opened. AG. Volkswagen A
n G do
wage es n
Volks ot g
by ua
ed ran
oris tee
– Separate quick-release fastener -2-a(black
ut
h or with black mark‐ or
ac
ing) of fuel supply line. ss

ce
le
un

pt
– Connect suitable line from pressure tester - VAS 6551- to fuel

an
d
itte

supply line.

y li
erm

ab
ility
– Hold the open end of the hose in a fuel-resistant beaker and
ot p

secure the beaker firmly by hand. A second mechanic may be

wit
is n

h re
needed to assist here.
ole,

spec
urposes, in part or in wh

– Carry out Guided Function Check electronic fuel pump

t to the co
(s) using ⇒ Vehicle diagnostic tester.

• The fuel pump will be activated for 30 seconds.

rrectne
– When fuel stops flowing, read amount of fuel delivered as in‐
dicated on measuring beaker.

ss
• Specification for 1.6-l common rail: at least 800 ml/30 seconds.

o
cial p

f inform
• Specification for 2.0-l common rail: at least 1000 ml/30 sec‐
mer

onds. atio
om

n
c

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or

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te

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Prote AG.

7. Fuel pump 83
 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

If specification is not attained

– Check fuel supply line between fuel pump and engine com‐
partment for damage.
– Renew damaged line and repeat test.
– If line is kinked, crushed or damaged, separate fuel supply line
-1- on front right of fuel tank.
– Connect suitable line from pressure tester - VAS 6551- to fuel
supply line -1-.
– Hold the open end of the hose in a fuel-resistant beaker and
secure the beaker firmly by hand. A second mechanic may be
needed to assist here.
AG. Volkswagen AG d
– Depending on software version, carry out Guided wageFunction
n oes
olks not
Check electric fuel pump(s) or Drain y V fuel system gu
db ara
using ⇒ Vehicle diagnostic tester. orise nte
eo
h
ut ra
• The fuel pump will be activated sfor
s a 30 seconds. c

ce
e
nl

– When fuel stops flowing, read amount of fuel delivered as in‐

pt
du

an
dicated on measuring beaker.
itte

y li
erm

ab
• Specification for 1.6-l common rail: at least 800 ml/30 seconds.

ility
ot p

wit
, is n

• Specification for 2.0-l common rail: at least 1000 ml/30 sec‐

h re
onds.
hole

spec
es, in part or in w

If specification is not attained

t to the co
– Lower fuel tank ⇒ page 31 .
– Repeat check directly at fuel delivery unit .

rrectness of i
– Check voltage supply and current draw of fuel pump
l purpos

⇒ page 72 .
– Check filter strainer of fuel delivery unit for soiling, and clean

nform
ercia

it as required.
m

at
om

i
If specification is attained
on
c

in t
or

Check fuel supply line between fuel tank and coupling station in
his
ate

engine compartment for flow, and renew it if necessary.

do
priv

cum
for

en
ng

t.
7.1.5 Checking delivery rate of fuel pump , en‐
yi Co
Cop py

gine codes CUUB, CUUC, CUUD,

t. rig
gh ht
pyri by
Vo
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CUUE, CUUF, DFSB, DFSC, DFSD,
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DFSE, DFSF
Special tools and workshop equipment required
♦ Hand multimeter - V.A.G 1526 E-

84 Rep. gr.20 - Fuel supply system

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

♦ Test instrument adapter/DSO (5-pin) - VAS 5565-

♦ Pressure tester (diesel) - VAS 6551-

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nl

pt
du

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itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

♦ Vehicle diagnostic tester

♦ Measuring container, fuel-resistant t to the co
Test conditions
rrectness of i

• Delivery pressure of fuel pump (fuel low pressure) checked

l purpos

beforehand.
• Fuel tank at least 75% full.
nform
ercia

• Battery voltage at least 12.5 V

m

at
om

ion

Sequence of operations
c

in t
or

his
te

– Lower fuel tank ⇒ page 31 .

a

do
priv

cum
for

en
ng

WARNING
t.
yi Co
Cop py
t. rig
gh ht
The fuel line is under pressure. yri
p by
co Vo
by lksw
cted
Fuel poses danger of injury to eyes and skin.
agen
Prote AG.

Wear protective goggles and protective clothing to avoid injury

and contact with the skin. Wrap a cloth around the connection
before loosening hose connections. Then reduce pressure by
carefully opening the connection.

– Pull fuel supply line (black or black marking) -2- off fuel delivery
unit.
– Collect escaping fuel with a cleaning cloth.

7. Fuel pump 85
 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

– Attach connection -A- of pressure tester (diesel) - VAS 6551-

to open end of fuel delivery unit using suitable line from pres‐
sure tester (diesel) - VAS 6551- .
– Close shut-off taps -B- and -C- on pressure tester (diesel) -
VAS 6551- .

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o ot g
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d ran
ir se tee
o
– Hold the open end of the hose at connection
auth -B- in a fuel-re‐ or
ac
sistant beaker and secure the beaker firmly
ss by hand. A second
mechanic may be needed to assist here.

ce
e
nl

pt
du

an
itte

– Switch on pressure tester (diesel) - VAS 6551- .

y li
erm

ab
ility
– Switch on ignition.
ot p

wit
, is n

– Connect ⇒ Vehicle diagnostic tester.

h re
hole

spec
– Select Guided Function Check electric fuel pump(s) .
es, in part or in w

t to the co
Note

rrectness of i
The fuel pump will be activated for 30 seconds.
l purpos

– Slowly open shut-off tap -B-.

nform
ercia

– Slowly close shut-off tap -B-.

m

at
om

ion
– While closing, read pressure indicated on pressure tester (die‐
c

in t
or

sel) - VAS 6551- .

his
ate

do
riv

– Set specification of 5 ± 0.2 bar by carefully closing.

p

cum
for

en
ng

– Empty measuring beaker.

t.
yi Co
Cop py
. rig
– Repeat Guided Function Check electric fuel pump(s) .
t
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note

The amount of fuel delivered by the fuel pump depends on the

voltage at the fuel delivery unit.

– Connect hand-held multimeter - V.A.G 1526 E- to connections

-1- and -5- of test instrument adapter/DSO (5-pin) - VAS
5565- .
Test conditions
• At room temperature (RT) or a fuel temperature of T = (20 ±
5)°C
• At a pressure of 5 ± 0.2 bar at flange output
• During the check, voltages ranging from 11 to 15 volts must
be evident at the fuel pump (measured at flange connector of
fuel delivery unit).
– Carry out guided function Checking electronic fuel pump
(s) .

86 Rep. gr.20 - Fuel supply system

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

– Compare amount of fuel delivered with the value gleaned from

the table.
*) Delivered amount of fuel in ml/30 s
**) Voltage at fuel delivery unit (V) with engine not running and
pump running
Reading example:
During the test, a voltage of 12.0 volts, for example, is measured
at the fuel delivery unit.
The delivered amount of fuel is therefore 1100 ml/30 s.
If the required amount of delivered fuel is achieved, or if more is
measured: fuel pump is OK.
If the amount of fuel to be delivered by the fuel pump is not ach‐
ieved, the following faults may have occurred: en AG. V
olkswagen AG
ag does
ksw not
♦ Battery voltage below 12.5 V y Vol gu
b ara
ed nte
ris
♦ Filter strainer of fuel delivery unit soiled;
tho check filter strainer eo
for soiling s au ra
c
s

ce
e

♦ Voltages ranging from 11 to 15 V were not reached during the

nl

pt
du

an
check
itte

y li
erm

ab
♦ Check voltage supply of fuel pump ⇒ page 72

ility
ot p

wit
, is n

♦ Checking current draw of fuel pump ⇒ page 72

h re
hole

spec
7.2 Supplementary fuel pump - V393-
es, in part or in w

t to the co
⇒ “7.2.1 Assembly overview - supplementary fuel pump V393 ”,
page 87

rrectness of i
⇒ “7.2.2 Checking supplementary fuel pump V393 ”, page 88
l purpos

⇒ “7.2.3 Removing and installing supplementary fuel pump V393

”, page 90

nform
ercia

7.2.1 Assembly overview - supplementary fuel pump - V393-

m

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
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Cop py
t. rig
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pyri by
Vo
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by
cted agen
Prote AG.

7. Fuel pump 87
 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

1 - Electrical connector
2 - Bolt
❑ 9 Nm
3 - Bolt
❑ 20 Nm
4 - Bracket
5 - Rubber mounting
6 - Fuel supply hose
❑ From fuel filter.
❑ White marking
7 - Spring-type clip
AG. Volkswagen AG d
agen
8 - Bolt olksw
oes
not
byV gu
ara
❑ 9 Nm rised
nte
ho eo
ut
9 - Bracket ss a ra
c

ce
e

10 - Rubber mounting
nl

pt
du

an
itte

y li
11 - Fuel supply hose
erm

ab
❑ To high-pressure pump
ility
ot p

wit
, is n

❑ White marking
h re
hole

12 - Spring-type clip spec

es, in part or in w

t to the co
13 - Supplementary fuel pump
- V393-
❑ Removing and installing
rrectness of i

⇒ page 90
l purpos

14 - Cable bracket
nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
a

7.2.2 Checking supplementary fuel pump -

iv

o
r
rp

cu

V393-
o

m
f

en
ng

t.
yi Co
op
Special tools and workshop equipment required
C py
ht. rig
rig ht
py by
♦ K-Jetronic pressure tester - V.A.G 1318- co Vo
by lksw
cted agen
Prote AG.

Test conditions:
• Battery voltage at least 12.5 V.
• Fuel filter OK.
• Fuel tank: level at least »reserve«.

88 Rep. gr.20 - Fuel supply system

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

• Ignition switched off

Carry out the following work:
– Wrap a clean cloth around the connection before opening the
fuel system. Then release pressure by carefully pulling hose
off connection.
– Pull fuel supply line -arrow- off high-pressure pump.

– Connect K-Jetronic pressure tester - V.A.G 1318- with suitable

adapter -2- to fuel supply line -1-. Connect other adapter -3-
from K-Jetronic pressure tester - V.A.G 1318- to open con‐
nection on high pressure pump.

AG. Volkswagen AG d
agen oes
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d by ara
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or eo
h
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ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

7. Fuel pump 89
 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

Note

The K-Jetronic pressure tester - V.A.G 1318- must be inserted as

an intermediate element into the fuel supply line.

– Connect vehicle diagnostic tester , and carry out guided func‐

tion “Check electrical fuel pump(s)”.

Note wage
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The fuel pump will be activated for 30 [Link] ran
tee
th or
au ac
s
– Run fuel pumps until highest fuel pressure has built up.
s

ce
e
nl

pt
du

• Specification: at least 3.5 bar

an
itte

y li
erm

ab
If specification is not obtained

ility
ot p

wit
Check threaded connection between pressure tester and fuel line
, is n

h re
for leaks.
hole

spec
Check pressure tester for leaks.
es, in part or in w

t to the co
Check fuel lines and their connections for leaks.
Check whether fuel filter is blocked.

rrectness of i
Check fuel delivery rate of fuel system pressurisation pump - G6-
l purpos

⇒ page 82 .

nform
ercia

Note
m

at
om

io
Check fuel system for leaks.

n
c

in t
or

his
ate

do
priv

7.2.3 Removing and installing supplementary cum

for

en
ng

t.
fuel pump - V393-
yi Co
Cop py
t. rig
gh ht
Special tools and workshop equipment required pyri by
Vo
co lksw
by
cted
♦ Hose clamp pliers - VAS 6340-
agen
Prote AG.

90 Rep. gr.20 - Fuel supply system

 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

♦ Torque wrench (5 … 50 Nm) - V.A.G 1331- AG. Volkswagen AG d

agen oes
olksw not
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d by ara
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or eo
h
aut ra
ss c

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le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
Removing

rrectne
– Detach connector -2- and unscrew bolt -3-.
– Remove bracket with pressure difference sender - G505- by

ss
pushing in direction of -arrow-.

o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
– Separate fuel return line -1- and fuel supply line -2- Prote
cted AG.
agen
⇒ “4.1 Separating plug-in connectors”, page 52 .
– Unhook fuel hoses -1, 2, 3- on bracket and remove bracket
-4-.

– Disconnect electrical connector -1-, pressing release mecha‐

nism to do so.
– Unscrew bolts -3, 4- and remove bracket -2- with supplemen‐
tary fuel pump.

7. Fuel pump 91
 Caddy 2016 ➤
Fuel supply system - Diesel engines - Edition 04.2019

– Unscrew bolts -1, 2, 3- and remove bracket -4-.

n AG. Volkswagen AG do
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o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
– Remove electrical connector -1- from bracket
ss and from wire
retainer -arrow-.

ce
le
un

pt
an
d
itte

– Remove supplementary fuel pump -6- with rubber mountings

y li
rm

ab
-5, 7- from bracket -3-.
pe

ility
ot

– Remove fuel hoses -2- and -4-.

wit
, is n

h re
hole

Installing

spec
es, in part or in w

Install in reverse order of removal. During this procedure, observe

t to the co
the following:
♦ Rout fuel hoses free of kinks.

rrectness of i
♦ Ensure fuel hoses are seated correctly.
l purpos

♦ Do not interchange fuel supply and return lines (return line is

blue or with blue markings and supply line is white or with white

nform
ercia

markings).
m

a
♦ Clip fuel and coolant hoses into retainers again.
com

tion in
– Fill/bleed fuel system ⇒ Rep. gr. 23 ; Injection system; Filling/
r
te o

thi
bleeding fuel system .

s
iva

do
r
rp

cum
fo

Specified torque for bolt of retainer for pressure differential sender en

ng

t.
yi
- G505-
Co
Cop py
t. rig
gh ht
yri
Bolt Specified torque/turning further angle p by
co Vo
by lksw
cted agen
-Item 3- 8 Nm Prote AG.

92 Rep. gr.20 - Fuel supply system