Volkswagen CC 2012 Workshop Manual
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Volkswagen CC 2012 Workshop Manual

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Service
Workshop Manual
CC 2012 ➤
Passat 2011 ➤
Passat Variant 2011 ➤
Fuel Supply System, petrol engines
Engine ID
Edition 05.2019
Service Department. Technical Information
CKM
BWS CCZ
A
B
CTH
CZD
D
A
CCT
CBF
CDA
A
A
A
CDA
CNN
CAV
B
A
D

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Summary of Contents for Volkswagen CC 2012

  • Page 1 Service Workshop Manual CC 2012 ➤ Passat 2011 ➤ Passat Variant 2011 ➤ Fuel supply system, petrol engines BWS CCZ Engine ID Edition 05.2019 Service Department. Technical Information...
  • Page 2 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 D3E803AE08C...
  • Page 3 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Contents 00 - Technical data ........... .
  • Page 4 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Contents...
  • Page 5 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 00 – Technical data Safety information (VRL013019; Edition 05.2019) ⇒ “1.1 Safety regulations for working on fuel supply”, page 1 ⇒...
  • Page 6 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Safety precautions when working on vehicles with a start/stop system Risk of injury from engine starting unexpectedly If the vehicle's start/stop system is activated, the engine can start unexpectedly.
  • Page 7 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Identification ⇒ “2.1 Engine number/engine data”, page 3 Engine number/engine data Codes CKMA CAVD CTHD CZDA CCZB CDAA Exhaust emission standard...
  • Page 8 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 General information ⇒ “3.1 Rules for cleanliness when working on auxiliary/supple‐ mentary heater and fuel system”, page 4 Rules for cleanliness when working on...
  • Page 9 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Repair notes ⇒ “4.1 Routing and attaching lines”, page 5 ⇒ “4.2 General repair instructions”, page 5 Routing and attaching lines Danger of damage to lines Lines may become damaged from moving or hot components.
  • Page 10 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 20 – Fuel supply system Fuel ⇒ “1.1 Assembly overview - fuel tank”, page 6 ⇒ “1.2 Emptying fuel tank”, page 14 ⇒...
  • Page 11 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 9 - Heat shield 10 - Clamping washer 11 - Bolt ❑ Renew after removal ❑ 25 Nm 12 - Seal ❑...
  • Page 12 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 1.1.2 Assembly overview - fuel tank, vehicles with front-wheel drive with engine codes CBFA, CCTA, CNNA 1 - Fuel line ❑...
  • Page 13 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 ❑ Checking fuel pump ⇒ page 73 ❑ Removing and installing fuel gauge sender - G- ⇒ page 111 ❑ Clean strainer if soiled ❑...
  • Page 14 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 1.1.3 Assembly overview - fuel tank, vehicles with four-wheel drive 1 - Supply line ❑ Clipped onto fuel tank ❑ Ensure firm seating 2 - Locking ring ❑...
  • Page 15 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 ❑ Removing and installing ⇒ “9.2 Removing and installing fuel gauge sender 2 G169 ”, page 112 14 - Fuel ❑...
  • Page 16 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 1.1.4 Assembly overview - fuel tank, vehicles with four-wheel drive with engine code CNNA 1 - Supply line ❑ Clipped onto fuel tank ❑...
  • Page 17 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 14 - Fuel gauge sender 2 - G169- ❑ Note installation position on fuel tank ⇒ page 112 ❑ Removing and installing ⇒...
  • Page 18 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Emptying fuel tank ⇒ “1.2.1 Emptying fuel tank when fuel pump is intact”, page 14 ⇒ “1.2.2 Emptying fuel tank if it is more than 3/4 full”, page 17 ⇒...
  • Page 19 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Note If the fuel extraction unit - VAS 5190- is still fitted with the extrac‐ tion hose with a fixed tip, the extraction hose must be replaced with the version with a screw-in tip.
  • Page 20 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – To do this, unclip right cover -1- at retaining tabs -arrows- using removal wedge - 3409- . Vehicles with auxiliary heater –...
  • Page 21 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – Connect test instrument/DSO adapter (5-pin) - VAS 5565- to connector and fuel delivery unit. – Connect remote control - V.A.G 1348/3A- to adapter - VAS 5565- and to battery positive (+) terminal.
  • Page 22 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – Make a mark -arrow- at distance -a- = 990 mm from end of extraction hose. – Use insulating tape for this.
  • Page 23 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Special tools and workshop equipment required ♦ Removal wedge - 3409- ♦ Special wrench - T10202- ♦ Torque wrench - V.A.G 1332- ♦...
  • Page 24 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – Remove right cover with fuel pump control unit - J538- -2- from assembly opening above fuel delivery unit. – To do this, unclip right cover -1- at retaining tabs -arrows- using removal wedge - 3409- .
  • Page 25 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Continued for all vehicles – Pull connector -1- off flange -3-. – Release connector -1- and fuel line -2- and pull them off flange -3-.
  • Page 26 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Special tools and workshop equipment required ♦ Removal wedge - 3409- ♦ Special wrench - T10202- ♦ Torque wrench - V.A.G 1332- ♦...
  • Page 27 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Emptying fuel tank at fuel delivery unit flange – Remove bench seat or fold it upwards ⇒ General body repairs, interior;...
  • Page 28 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Continued for all vehicles – Pull connector -1- off flange -3-. – Disconnect fuel line -2- at flange -3-. Separate plug-in con‐...
  • Page 29 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – Open locking ring using wrench - T10202- . – Do not cant key - T10202- and press against locking ring firmly.
  • Page 30 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Removing and installing fuel tank ⇒ “1.3.1 Removing and installing fuel tank - vehicles with front- wheel drive”, page 26 ⇒...
  • Page 31 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 ♦ Torque wrench - V.A.G 1332- Removing Note ♦ The rear axle must be lowered to remove the fuel tank.
  • Page 32 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Vehicles with auxiliary heater – Remove connector -1- from cover -3-. – Release connectors -1- and pull off. – Unclip sealing grommet -2- downwards from cover -3-.
  • Page 33 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Continuation for all other engine codes: – Pull breather line and pressure retention valve -arrow- off ac‐ tivated charcoal filter. Separate plug-in connectors ⇒...
  • Page 34 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – Release and pull off connector -arrow- at metering pump - V54- . Continued for all vehicles – Lower rear axle ⇒ Running gear, axles, steering; Rep. gr. 42 ;...
  • Page 35 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – Check whether there are signs of oxidation on the earth wire of the connectors, remove if necessary. – Check installation position of earth connection.
  • Page 36 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 ♦ Removal wedge - 3409- ♦ Engine and gearbox jack - V.A.G 1383 A- ♦ Torque wrench - V.A.G 1332-...
  • Page 37 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – Open fuel tank flap. – Remove cap -arrow- from fuel filler neck. – Clean area around fuel filler neck.
  • Page 38 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – Release and pull fuel delivery line -2- from flange -1-. Separate plug-in connectors ⇒ page 51 Continued for all vehicles –...
  • Page 39 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Vehicles with engine code BWS or CCZB: – Pull breather line and pressure retention valve -arrow- off ac‐ tivated charcoal filter.
  • Page 40 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – Attach front exhaust pipe to tunnel bridge by wire. – Remove propshaft ⇒ Rep. gr. 39 ; Propshaft; Removing and installing propshaft .
  • Page 41 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – Pull breather line -1- and supply line -2- off at separating point. Separate plug-in connectors ⇒ page 51 Vehicles with auxiliary heater –...
  • Page 42 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Continued for all vehicles – Place engine and gearbox jack - V.A.G 1383 A- under fuel tank to support it.
  • Page 43 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – Secure fuel tank. – Guide filler neck in between rear axle and body. – Use suitable workshop equipment to prevent the securing straps from turning while tightening the bolts.
  • Page 44 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – Fit connector -arrow- to left flange. Ensure connections are secured properly by pulling. – Note installation position of covers -arrows-.
  • Page 45 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Fuel delivery unit, fuel gauge sender ⇒ “2.1 Assembly overview - fuel delivery unit/fuel gauge sender”, page 41 ⇒ “2.2 Removing and installing fuel delivery unit, fuel gauge send‐...
  • Page 46 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Installation position of fuel delivery unit • Tab -2- on flange must be between lugs -1- and -3- on fuel tank.
  • Page 47 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Removing and installing fuel delivery unit, fuel gauge sender ⇒ “2.2.1 Removing and installing fuel delivery unit, fuel gauge sender”, page 43 ⇒...
  • Page 48 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – Remove right cover with fuel pump control unit - J538- -2- from assembly opening above fuel delivery unit. – To do this, unclip right cover -1- at retaining tabs -arrows- using removal wedge - 3409- .
  • Page 49 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Continued for all vehicles – Release connector -1- and pull off. – Release fuel line -2- and pull it off fuel delivery unit flange -3-.
  • Page 50 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Vehicles with front-wheel drive – Release and separate plug-in connector -2-. Separate plug-in connectors ⇒ page 51 – Release suction line -1- -arrows- and pull off.
  • Page 51 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Vehicles with front-wheel drive – Attach suction line of suction-jet pump -arrows- and click in place. – Reconnect plug-in connector -2-.
  • Page 52 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – With flange in installation position, push it downwards against spring force. • The tab -2- of the sealing flange must be between lugs -1- and -3-.
  • Page 53 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – The fuel tank must not be more than / 4 full. This ensures that the fill level is below the flange of the fuel delivery unit.
  • Page 54 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 If fuel line for metering pump - V54- is to be disconnected from fuel delivery unit: – Open lower clip -3- on flange -1-.
  • Page 55 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Plug-in connectors ⇒ “3.1 Separating plug-in connectors”, page 51 Separating plug-in connectors Special tools and workshop equipment required ♦ Lever - T10468-...
  • Page 56 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Version 1 Plug-in connector with release buttons -arrows- on right and left: Open Counterhold at the coupling point for fuel -1- in the engine com‐...
  • Page 57 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Version 2 Plug-in connector with pull-release mechanism -arrow-. Open – Push plug-in connector -1- in -direction of arrow A-. – Pull pull-release mechanism -2- in -direction of arrow B-.
  • Page 58 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Version 5 Plug-in connector with release buttons -arrows- on right and left: Open – Press release buttons -arrows- and pull off plug-in connector.
  • Page 59 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Fuel filter Pressure limiting valve and fuel filter are integrated in fuel delivery unit and cannot be renewed individually ⇒ page 43...
  • Page 60 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Activated charcoal filter with fuel tank leak detection ⇒ “5.1 Assembly overview – activated charcoal filter system”, page 56 ⇒ “5.2 Removing and installing activated charcoal filter”, page 57 ⇒...
  • Page 61 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 12 - Breather line ❑ From fuel tank 5.1.2 Assembly overview - activated charcoal filter system, vehicles with addi‐ tional filter and engine codes CBFA, CCTA...
  • Page 62 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – Release connector -1- and pull off. – Pull off breather lines -2- and -3- from activated charcoal filter. – Remove securing bolt -arrow-.
  • Page 63 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 ♦ Hose clamps to 25 mm - 3094- The plug-in connectors for fuel, vacuum and breather lines are colour coded. There is either a coloured dot on the plug-in con‐...
  • Page 64 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – Connect adapter hose - KLI 9210/55-1- to breather line -A- (colour code: white). – Connect test hose -G- of fuel system tester - KLI 9210- to adapter hose - KLI 9210/55-1- .
  • Page 65 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – Clamp off hose to activated charcoal filter solenoid valve 1 - N80- using hose clamps, up to Ø 25 mm - 3094- -arrow-.
  • Page 66 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – First check activated charcoal filter solenoid valve 1 - N80- for leaks. To do this, clamp off hose to activated charcoal filter solenoid valve 1 - N80- using hose clamps, up to Ø...
  • Page 67 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – Clamp off hose between fuel system diagnostic pump - V144- and air filter -arrow-. – Set valve -D- to “Test”.
  • Page 68 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 1 - Activated charcoal filter 2 - Location of adapter hose - KLI 9210/55-1- ❑ For leak detection in fuel system 3 - Activated charcoal filter sol‐...
  • Page 69 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Note The fuel system diagnostic pump - V144- is fitted in the rear right wheel housing behind the wheel housing liner.
  • Page 70 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Activated charcoal filter without fuel tank leak detection ⇒ “6.1 Assembly overview – activated charcoal filter system”, page 66 ⇒ “6.2 Removing and installing activated charcoal filter”, page 66 ⇒...
  • Page 71 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – Disconnect breather lines -2- and -3- from activated charcoal filter. Separate plug-in connectors ⇒ “3.1 Separating plug-in connectors”, page 51 –...
  • Page 72 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Note Plug-in connectors for fuel lines must engage »audibly« when ♦ joined. Note colour assignment when installing the plug-in connectors ♦...
  • Page 73 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – Seal breather hole in activated charcoal filter -arrow- and op‐ erate vacuum pump again several times. Vacuum must build –...
  • Page 74 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Accelerator pedal ⇒ “7.1 Assembly overview - accelerator module”, page 70 ⇒ “7.2 Removing and installing accelerator pedal module GX2 ”,...
  • Page 75 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 ♦ Release tool - T10238- ♦ Release tool - T10240- (for right-hand drive) Removing – Lever cover cap -3- out with a screwdriver.
  • Page 76 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Installing – Push connector -1- onto accelerator module -4-. – Push accelerator module onto retaining pins -5-. – Insert centring pin -6- into hole in underbody.
  • Page 77 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Fuel pump ⇒ “8.1 Checking fuel system pressurisation pump G6 ”, page 73 ⇒ “8.2 Removing and installing suction-jet pump”, page 106...
  • Page 78 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 ♦ Adapter set - V.A.G 1594C- ♦ Vehicle diagnostic tester Test conditions: • Battery voltage must be at least 11.5 V. If necessary, charge battery ⇒...
  • Page 79 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – Check that connector -arrow- is fitted securely by pulling con‐ nector without pressing catch. If connector was not inserted correctly, repeat functional check of fuel pump.
  • Page 80 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Vehicles with auxiliary heater – Remove connector -1- from cover -3-. – Release connectors -1- and pull off. – Unclip sealing grommet -2- downwards from cover -3-.
  • Page 81 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 ♦ Pressure gauge - VAS 6550- ♦ Removal wedge - 3409- ♦ Vehicle diagnostic tester Test conditions: • Voltage supply OK ⇒...
  • Page 82 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – Connect pressure tester - VAS 6550- to fuel supply line using hose - VAS 6550/1- and -VAS 6550/2- .
  • Page 83 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – If fitted, remove fuel pump control unit - J538- -2- from cover on right. – Unclip right cover -1- at retaining tabs -arrows-, using removal wedge - 3409- .
  • Page 84 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Continued for all vehicles: – Pull fuel line -2- off flange of fuel delivery unit -2-. Separate plug-in connectors ⇒ “3.1 Separating plug-in connectors”, page 51 –...
  • Page 85 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – Ensure that drain tap -C- on pressure tester -1- is closed. – Shut-off valves -A- and -B- on pressure tester -1- are open.
  • Page 86 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 ♦ Pressure gauge - VAS 6550- ♦ Removal wedge - 3409- ♦ Vehicle diagnostic tester – Remove bench seat or fold it upwards ⇒ General body repairs, interior;...
  • Page 87 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Vehicles with auxiliary heater – Remove connector -1- from cover -3-. – Release connectors -1- and pull off. – Unclip sealing grommet -2- downwards from cover -3-.
  • Page 88 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – Ensure that drain tap -C- on pressure tester - VAS 6550- -1- is closed. – Shut-off valves -A- and -B- on pressure tester - VAS 6550- -1- are open.
  • Page 89 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 • Fuel pressure OK and pressure tester - VAS 6550- connected. Check fuel pressure ⇒ “8.1.2 Checking fuel pressure”, page 76 CAUTION Risk of fire due to escaping fuel.
  • Page 90 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – Ensure that drain tap -C- is closed and shut-off taps -A- and -B- on pressure tester - VAS 6550- -1- are open.
  • Page 91 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – To do this, unclip right cover -1- at retaining tabs -arrows- using removal wedge - 3409- . Vehicles with auxiliary heater –...
  • Page 92 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – Connect pressure tester - VAS 6550- with adapter - VAS 6550/1- and adapter - VAS 6550/2- between fuel supply line and fuel delivery unit.
  • Page 93 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Special tools and workshop equipment required ♦ Removal wedge - 3409- ♦ Remote control for V.A.G 1348 - V.A.G 1348/3A- ♦...
  • Page 94 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 ♦ Measuring container, capacity: 3 litres Test conditions: • Voltage supply OK ⇒ “8.1.1 Checking function and voltage supply”, page 73 •...
  • Page 95 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Vehicles with auxiliary heater – Remove connector -1- from cover -3-. – Release connectors -1- and pull off. – Unclip sealing grommet -2- downwards from cover -3-.
  • Page 96 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – The quantity delivered by the fuel pump depends on the bat‐ tery voltage. Therefore, also connect hand-held multimeter - V.A.G 1526E- to contacts -1- and -5- of adapters - VAS 5565- .
  • Page 97 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – Ensure that drain tap -C- on pressure tester -1- is closed. – Shut-off valves -A- and -B- on pressure tester -1- are open.
  • Page 98 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – Pull supply line -arrow- off at flange and catch escaping fuel with a cloth. Separate plug-in connectors ⇒ “3.1 Separating plug-in connectors”, page 51 –...
  • Page 99 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – Set pressure of 4.0 bar on pressure regulating valve -arrow- using adjuster wheel. – From this point on do not change position of adjuster wheel any more.
  • Page 100 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – Compare delivered quantity of fuel with specification indicated in chart. Name of axis Unit Quantity of fuel delivered Voltage at fuel pump with en‐...
  • Page 101 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Special tools and workshop equipment required ♦ Removal wedge - 3409- ♦ Remote control for V.A.G 1348 - V.A.G 1348/3A- ♦...
  • Page 102 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 ♦ Measuring container, capacity: 3 litres Note The fuel delivery rate must first be checked in the engine com‐ ♦...
  • Page 103 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 If specification is not obtained – Open tank flap unit. – Clean area around fuel filler neck. – Unscrew cap from fuel filler neck -arrow-.
  • Page 104 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – Remove right cover with fuel pump control unit - J538- -2- from assembly opening above fuel delivery unit. – To do this, unclip right cover -1- at retaining tabs -arrows- using removal wedge - 3409- .
  • Page 105 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Continued for all vehicles – Pull connector -1- off flange -3-. – Check contacts on plug and on fuel delivery unit for damage.
  • Page 106 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – Connect pressure tester - VAS 6550- to flange using hose - VAS 6550/2- . – Connect hose - VAS 6550/2- to connection -A- of pressure tester - VAS 6550- .
  • Page 107 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – Compare delivered quantity of fuel with specification indicated in chart. Name of axis Unit Quantity of fuel delivered Voltage at fuel pump with en‐...
  • Page 108 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 ♦ Removal wedge - 3409- ♦ Multimeter, e.g. hand-held multimeter - V.A.G 1526E- ♦ Pick-up clamp e.g. pick-up clamp - V.A.G 1526B/2- ♦...
  • Page 109 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – Remove right cover with fuel pump control unit - J538- -2- from assembly opening above fuel delivery unit. – To do this, unclip right cover -1- at retaining tabs -arrows- using removal wedge - 3409- .
  • Page 110 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Continued for all vehicles – Pull connector -1- off flange -3-. – Check contacts on plug and on fuel delivery unit for damage.
  • Page 111 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 ♦ Special wrench - T10202- ♦ Torque wrench - V.A.G 1332- ♦ Removal wedge - 3409- 8. Fuel pump...
  • Page 112 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 On vehicles with four-wheel drive the fuel tank is divided into a left and a right chamber. Use suction-jet pump -2- to move fuel from left fuel tank chamber to baffle housing of fuel delivery unit -1- on right.
  • Page 113 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – Disconnect connector to four-wheel drive control unit - J492- -arrow-. – Unclip sealing grommet -1- downwards from cover. – Guide wiring harness of all-wheel drive control unit - J492- out downwards.
  • Page 114 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – Connect suction-jet pump -B- and line -A- to fuel delivery unit. – Pull to check engagement. • When installing do not bend fuel gauge sender 2 - G169- float arm.
  • Page 115 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 Senders and sensors ⇒ “9.1 Removing and installing fuel gauge sender G ”, page 111 ⇒ “9.2 Removing and installing fuel gauge sender 2 G169 ”, page...
  • Page 116 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – Pull fuel gauge sender - G- slightly to side and upwards at the same time. – If the sender cannot be released in this way, push the securing tabs -arrows- to the side slightly.
  • Page 117 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 ♦ Special wrench - T10202- ♦ Torque wrench - V.A.G 1332- ♦ Removal wedge - 3409- Condition: • The fuel tank must not be more than / 4 full.
  • Page 118 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – Unclip right cover -1- at retaining tabs -arrows-, using removal wedge - 3409- . – Disconnect connector to four-wheel drive control unit - J492- -arrow-.
  • Page 119 CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ Fuel supply system, petrol engines - Edition 05.2019 – Pull fuel gauge sender 2 - G169- upwards a little. – Unclip locking lugs -arrows- of suction-jet pump. Installing Install in reverse order of removal.

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