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Workshop Manual
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Phaeton 2003 ➤
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Fuel supply system - Diesel engines
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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 © 2015 Volkswagen AG, Wolfsburg D3E80404AD4

Phaeton 2003 ➤
Fuel supply system - Diesel engines - Edition 09.2014
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1 Procedure when filling with incorrect fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Step 1 (Engine was started with incorrect fuel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Step 2 (Engine was not started with incorrect fuel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Step 3 (There are metal particles in fuel delivery unit and fuel tank) . . . . . . . . . . . . . . . . . . 6
1.4 Step 4 (There are no metal particles in fuel delivery unit and fuel tank) . . . . . . . . . . . . . . 6
1.5 Step 5 (There are metal particles in high-pressure pump) . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.6 Step 6 (There are no metal particles in high-pressure pump) . . . . . . . . . . . . . . . . . . . . . . 7
2 Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.3 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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3 Fuel delivery unit, fuel gauge sender . . . . . . . .lk.sw. a.g.e.n . . . . . . . . . . . .G.d.o.es. n.o. . . . . . . . . . . . 19
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3.1 Removing and installing fuel delivery unit,efuel yV
d b gauge sender . . . . . . . . . . . . u. a.ra. . . . . . . . 19
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4 Push-on connectors . . . . . . . . . . . . u.th.o. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . e.or. . . . . 25
a a
4.1 Detaching push-on couplings . . . .ss. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c. . . . 25
ce
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5 Fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
pt
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5.1 Removing and installing fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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6 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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6.1 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
, is n
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6.2 Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
hole
spec
6.3 Fuel hoses in engine compartment, engine code AJS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
es, in part or in w
t to the co
7 Accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.1 Assembly overview - accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
rrectness of i
8 Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8.1 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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8.2 Removing and installing fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

8.3 Assembly overview - supplementary fuel pump V393 , engine codes CARA, CEXA, CEXB
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........................................................................ 56
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Contents i
Phaeton 2003 ➤
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ii Contents
Phaeton 2003 ➤
00 – Technical data
1 Engine data
(VRL007330; Edition 09.2014)
Engine code AJS BMK CARA CEXA CEXB
Emission standards EU 3 EU 4 EU 4 EU 4 EU 5
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Capacity l 4.9 wagen AG
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Output kW ed by V230 165 175guara 176 180
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1. Engine data 1
Phaeton 2003 ➤
2 Safety precautions
⇒ “2.1 Safety precautions when working on fuel supply system”,
page 2
2.1 Safety precautions when working on

fuel supply system
WARNING
When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route all the various lines and electrical wiring so that they
are in their original positions.
♦ Ensure that there is sufficient clearance to all moving or
hot components.
♦ The fuel and the fuel lines in the fuel system can become
very hot (danger of scalding)!
♦ The fuel system is pressurised!
♦ Before opening the system place a cloth around the con‐
nection.
♦ Then, release pressure by carefully loosening the con‐
nection.
♦ Wear eye and hand protection when performing any type wage
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Bear in mind that the fuel pump can be activated due to open‐
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(fuel delivery unit) from a full or partly full fuel tank, observe the
following:
♦ Before starting work, the extraction hose of a switched-on ex‐
haust gas extraction system must be laid near to the assembly rrectness of i
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opening of the fuel tank. This draws away the fuel fumes that
escape. If no exhaust gas extraction system is available, a ra‐
dial fan with a displacement greater than 15 m3/h can be used
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♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!

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2 Rep. gr.00 - Technical data

Phaeton 2003 ➤
WARNING
Danger of burning from very hot fuel.

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Risk of injury due to highly-pressurised fuel.
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♦ To release pressure in fuel system, place clean cloth
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WARNING
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The fuel system is pressurised! Wear eye protection and pro‐
tective clothing to avoid eye injuries and skin contact. Before
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loosening hose connections, wrap a cloth around the connec‐

tion. Then release pressure by carefully pulling hose off con‐
nection.
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Do not damage fuel hoses in engine compartment.
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2. Safety precautions 3
Phaeton 2003 ➤
3 General repair notes

⇒ “3.1 Rules for cleanliness”, page 4
3.1 Rules for cleanliness

When working on the fuel supply and injection system, pay careful
attention to the following “6 rules” for cleanliness:
♦ Thoroughly clean all connections and surrounding areas be‐
fore disconnecting.
♦ Place removed parts on a clean surface and cover. Use only
lint-free cloths.
♦ Carefully cover opened components or seal if repairs cannot
be carried out immediately.
♦ Install clean components only. Do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have not been stored in their packing (e.g. in
tool boxes etc.).
♦ When the system is open: Do not work with compressed air.
Do not move vehicle unless absolutely necessary.
♦ Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses
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4 Rep. gr.00 - Technical data

Phaeton 2003 ➤
20 – Fuel supply system

1 Procedure when filling with incorrect
fuel
Caution
Irreversible damage to high-pressure components, especially

the high-pressure pump, can occur due to lack of lubrication
through diesel when filling the fuel tank with incorrect fuel.
Damage due to seizure and metal particles can be expected.
These metal particles may also cause further damage to pres‐
sure regulating valve and injectors. Test sample, if unsure of
fuel quality. Analyse fuel using Fuel analyser unit - VAS 6774-
⇒ Instruction manual . This analyser unit is no substitute for a
laboratory test in warranty cases.
Note
These instructions are intended to guide you through the individ‐

ual work steps by means of a flowchart, with various factors being
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Was the engine started with the incorrect fuel? au
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⇒ “1.1 Step 1 (Engine was started with incorrect fuel)”,
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1.1 Step 1 (Engine was started with incor‐
es, in part or in w
t to the co
rect fuel)
– Completely drain fuel tank with fuel extractor - VAS 5190-
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⇒ page 16 .
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– Remove fuel delivery unit ⇒ page 19 .

– Check fuel tank for metal particles.
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– Drain fuel pump reservoir of fuel delivery unit.

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– Carry out a visual inspection for foreign bodies and metal par‐
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ticles in fuel pump reservoir and on preliminary filter.

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⇒ “1.3 Step 3 (There are metal particles in fuel delivery unit
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⇒ “1.4 Step 4 (There are no metal particles in fuel delivery unit
and fuel tank)”, page 6
1.2 Step 2 (Engine was not started with in‐

correct fuel)
– Drain fuel tank with fuel extractor - VAS 5190- ⇒ page 19 .
1. Procedure when filling with incorrect fuel 5

Phaeton 2003 ➤
– Repeat procedure, if necessary, until fuel tank is completely

empty.
– Fill fuel tank with 5 litres of diesel fuel.
– Completely empty fuel tank again as described above.
– Renew fuel filter ⇒ Maintenance ; Booklet ; Fuel filter: Re‐
newing (diesel engine) .
– Fill up vehicle and perform road test.
End
1.3 Step 3 (There are metal particles in fuel

delivery unit and fuel tank)
– Clean fuel delivery unit and fuel tank with diesel extractor -
VAS 5226- .
– Install fuel delivery unit ⇒ page 19 .
– Renew following high-pressure components:
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♦ High-pressure pump ⇒ Rep. gr. 23 ; Removing
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♦ High-pressure lines ⇒ Rep. gr.
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high-pressure lines ss
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♦ High-pressure accumulator (rail) including fuel pressure reg‐

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Rep. gr. 23 ; Removing and installing high-pressure accumu‐ y li

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♦ Injector ⇒ Rep. gr. 23 ; Removing and installing injectors h re

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♦ Fuel return lines (leakage oil lines) ⇒ Rep. gr. 23 ; Assembly

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overview - fuel system

t to the co
♦ Fuel filter ⇒ Maintenance ; Booklet ; Fuel filter: Renewing

(diesel engine) .
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– Fill up vehicle.
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– Bleed fuel system ⇒ Rep. gr. 23 ; Filling/bleeding/checking

components of diesel direct injection system .
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– Perform road test.

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1.4 Step 4 (There are no metal particles in

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– Renew high-pressure pump ⇒ Rep. gr. 23 ; Removing and
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installing high-pressure pump
Caution
It is only permissible to do the following work when the defec‐

tive high-pressure pump has been removed.
6 Rep. gr.20 - Fuel supply system

Phaeton 2003 ➤
AG. Volkswagen AG d
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agen Fuel supply
oes system - Diesel
not engines - Edition 09.2014
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– Unscrew bolts -arrows-ris and remove metering unit -1- from theante
e
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OLD high-pressureau pump.
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– Check metering unit and high-pressure pump for filings.
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1.5 Step 5 (There are metal particles in high-
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– Renew following high-pressure components:
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♦ High-pressure lines ⇒ Rep. gr. 23 ; Removing and installing
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♦ Fuel return lines (leakage oil lines) ⇒ Rep. gr. 23 ; Assembly Prote
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overview - fuel system
♦ Fuel filter ⇒ Maintenance ; Booklet ; Fuel filter: Renewing
(diesel engine) .
– Fill up vehicle.
– Perform road test.
End
1.6 Step 6 (There are no metal particles in

high-pressure pump)
– Renew fuel filter ⇒ Maintenance ; Booklet ; Fuel filter: Re‐
newing (diesel engine) .
– Fill up vehicle and perform road test.
End
1. Procedure when filling with incorrect fuel 7

Phaeton 2003 ➤
2 Fuel tank
Note
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Hose connections are secured y V with either spring-type or t gua
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♦ Spring-type clip pliers - VAS 6362- or hose clip pliers - VAS
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6340- are recommended for installation of spring-type clips.
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⇒ “2.1 Assembly overview - fuel tank”, page 8
es, in part or in w
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⇒ “2.2 Removing and installing fuel tank”, page 15
⇒ “2.3 Emptying fuel tank”, page 16
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2.1 Assembly overview - fuel tank
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⇒ “2.1.1 Assembly overview - fuel tank”, page 8
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⇒ “2.1.2 Assembly overview - components on right-hand side in

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fuel tank”, page 10
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⇒ “2.1.3 Assembly overview - components on left-hand side in

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Phaeton 2003 ➤
1 - Cap agen
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2 - Securing bolt d by V gu
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4 - Fuel tank filler neck
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5 - Breather line
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6 - Fuel tank
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❑ When removing, sup‐
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gearbox jack - V.A.G
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❑ Removing and installing
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⇒ page 15
7 - Filler hose
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❑ From filler neck.
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8 - Aperture for left sender

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by lksw
⇒ page 10 .
cted agen
Prote AG.
10 - Aperture for supply and

return flange
11 - Heat shield
❑ For fuel tank.
12 - 20 Nm + turn 90° further
13 - Securing strap
❑ Note installation position.
14 - Cross member
❑ For fuel tank.
15 - Retaining clip
❑ Check for secure seating.
16 - From fuel filter.
17 - Fuel line
18 - To fuel filter
19 - To connection on supply and return flange
❑ ⇒ Item 8 (page 10)
20 - To connection on supply and return flange
21 - 8 Nm + turn 90° further
22 - Breather valve
2. Fuel tank 9
Phaeton 2003 ➤
2.1.2 Assembly overview - components on right-hand side in fuel tank
1 - Fuel pump 1 - V276-

⇒ page 19
2 - To Y-piece on supply line
for left suction-jet pump
❑
AG. Volkswagen AG d
3 - Supply line for suction-jet ksw
agen oes
not
l
pumps by Vo gu
ara
d
ise nte
4 - Connector uthor eo
a ra
❑ Coded connector to ss c
flange
ce
le
un
pt
⇒ Item 25 (page 11) .
an
d
itte
y li
rm
ab
5 - Fuel gauge sender 3 -
pe
ility
G237-
ot
wit
, is n
❑ Lever-type sender.
h re
hole
spec
❑ Clipped onto support for
es, in part or in w
fuel pump 1 - V276- .
t to the co
❑ Checking ⇒ Current flow
diagrams, Electrical
fault finding and Fitting
rrectness of i
locations.
l purpos
6 - Connection
❑ For fuel supply line
nform
ercia
⇒ Item 20 (page 11) .

m
❑ Arrow points away from
a
com
tio
connection.
n in
r
te o
thi
7 - Seal
s
iva
do
r
❑ Renew if damaged.
rp
cum
fo
en
ng
8 - Connection
t.
yi Co
Cop py
❑ For fuel return line.
t. rig
gh ht
yri by
❑ Arrow points towards cop Vo
by lksw
cted
connection.
agen
Prote AG.
9 - Supply and return flange

10 - Locking ring
❑ Loosen and tighten with wrench - 3087- .
❑ Specified torque: 60 Nm.
11 - Connector
❑ For fuel pump 1 - V276- .
❑ Coded connector to flange ⇒ Item 25 (page 11) .
12 - Connector
13 - Locking lug
❑ Clipped onto right of fuel pump.
14 - Fuel gauge sender - G-
❑ Plunger-type sender.
15 - Suction-jet pump
16 - Locking lug
❑ Clipped onto support for fuel pump.

Phaeton 2003 ➤
AG. VolkFuel supply
swagen AG
doesystem - Diesel engines - Edition 09.2014
agen
olksw s no
t gu
y V
b ara
17 - Supply line ris
ed nte
ho eo
❑ Suction-jet pump,
s a right side
ut ra
c
s
18 - Delivery line
ce
le
un
pt
an
d
❑ Suction-jet pump, right side itte
y li
rm
ab
19 - Return line
pe
ility
ot
wit
, is n
20 - Supply line
h re
hole
spec
21 - Non-return valve
es, in part or in w
t to the co
22 - To return line of fuel pump 2 - V277-
❑ ⇒ Item 20 (page 13)
rrectness of i
23 - From supply line of fuel pump 2 - V277-
❑ ⇒ Item 19 (page 13)
l purpos
24 - Locking ring
nform
ercia
❑ Specified torque: 145 Nm.

m
❑ Loosen and tighten with wrench - 3087- .
a
com
tion in
25 - Flange
r
te o
thi
❑ Note installation position on fuel tank ⇒ page 13 .
s
iva
do
r
rp
cum
26 - Seal
fo
en
ng
t.
yi
❑ Renew.
Co
Cop py
t. rig
27 - To fuel pump 2 - V277- .
gh ht
pyri by
Vo
co
❑ Clipped onto right of fuel pump.
by lksw
cted agen
Prote AG.
28 - From supply line for suction-jet pumps on fuel pump 2 - V277-
❑ ⇒ Item 10 (page 12)
29 - Filler hose connection
2. Fuel tank 11
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
Phaeton 2003 ➤ orise nte
h eo
Fuel supply system - Diesel engines -auEdition
t 09.2014 ra
c
ss
ce
e
nl
2.1.3 Assembly overview - components on left-hand side in fuel tank
pt
du
an
itte
y li
erm
ab
ility
ot p
1 - Fuel pump 2 - V277-
wit
, is n
h re
hole
⇒ page 22
spec
es, in part or in w
2 - Connector
t to the co
❑ For fuel pump 2 - V277- .
❑ Coded connector to
rrectness of i
flange
⇒ Item 6 (page 12) .
l purpos
3 - Locking ring
nf
ercia
❑ Specified torque:
or
145 Nm.
m
m
atio
m
❑ Loosen and tighten with

o
n in
c
wrench - 3087- .
or
thi
te
sd
iva
4 - Seal
o
r
rp
cu
o
m
❑ Renew.
f
en
ng
t.
yi Co
op
5 - Supply line C py
t. rig
gh ht
❑ For auxiliary heater. yri
p by
o Vo
by c lksw
cted
6 - Flange
agen
Prote AG.
❑ Note installation posi‐

tion on fuel tank
⇒ page 13 .
7 - Fuel gauge sender 2 -
G169-
❑ Plunger-type sender.
❑ Checking ⇒ Current flow
diagrams, Electrical
fault finding and Fitting
locations.
8 - Locking lug
❑ Clipped onto left of fuel
pump.
9 - Connector
10 - To supply line for suction-jet pump, right side
❑ ⇒ Item 28 (page 11)
11 - From supply line for suction-jet pumps on fuel pump 1 - V276-
12 - Supply line
❑ Suction-jet pump, left side
13 - Locking lug
15 - Delivery line
❑ Suction-jet pump, left side
16 - Fuel gauge sender 4 - G393-
❑ Lever-type sender.

Phaeton 2003 ➤
17 - Connector
18 - To fuel pump 1 - V276- .
❑ Clipped onto upper left of fuel pump.
19 - To supply line
❑ ⇒ Item 23 (page 11)
20 - From return line
❑ ⇒ Item 22 (page 11) AG. Volkswagen AG d
agen oes
olksw not
yV gu
21 - Return line ed b ara
nte
ris
ho eo
22 - Supply line aut ra
c
ss
ce
e
nl
pt
du
an
itte
Installation position of flange for fuel pumps
y li
erm
ab
ility
Insert sender flanges with marking -arrow- pointing in direction of
ot p
wit
travel.
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
or
2.1.4 Schematic diagram of fuel lines and components in fuel tank
m
m
atio
om
n in
c
A - Left side of tank.

or
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.
2. Fuel tank 13
. Volkswage
Phaeton 2003 ➤ wage
n AG n AG d
oes
olks not
d by V - Edition 09.2014 gu
ar
e an
ris tee
ho
B - Right side of tank. au
t or
ac
ss
ce
e
nl
pt
du
an
1 - Supply and return flange
itte
y li
erm
ab
2 - Supply line
ility
ot p
wit
3 - Return line
, is n
h re
hole
spec
es, in part or in w
❑ Right side.
t to the co
5 - Fuel pump 1 - V276-
❑ Right side.
rrectness of i
6 - Filler hose
l purpos
❑ From filler neck.
nform
ercia
7 - Y-piece
m
8 - Non-return valve
at
om
ion
c
9 - Y-piece
in t
or
his
ate
10 - Supply line for auxiliary
do
priv
c
heater
um
for
en
ng
t.
yi
11 - Flange
Co
Cop py
.
❑ Left side.
ht rig
rig ht
py by
co Vo
12 - Fuel pump 2 - V277-
by lksw
cted agen
Prote AG.
❑ Left side.
❑ Left side.
14 - Delivery line
❑ To fuel pump 1 - V276- .
15 - Y-piece
16 - Supply line for suction-jet
pumps
17 - Delivery line
❑ To fuel pump 2 - V277- .

Phaeton 2003 ➤
2.2 Removing and installing fuel tank
Special tools and workshop

equipment required lkswage es n
o ot g
yV ua
♦ Fuel extractor - VAS 5190- rised b ran
tee
tho
or
♦ Fuel tank sender unit tool au- ac
ss
3087-
ce
e
nl
pt
du
♦ Torque wrench - V.A.G
an
itte
y li
1331-
erm
ab
ility
ot p
wit
, is n
1332-
h re
hole
spec
♦ Engine and gearbox jack -
es, in part or in w
V.A.G 1383 A-
t to the co
rrectness of i
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.
Prerequisites:
• Fuel tank must be empty ⇒ page 16 .
Removing
– Observe safety precautions ⇒ page 2 .
– Remove rear bumper ⇒ Body Repairs; Rep. gr. 63 ; Rear
bumper; Removing and installing rear bumper .
– Remove rear right wheel housing liner ⇒ Body Repairs; Rep.
gr. 66 ; Removing and installing wheel housing liner .
– Remove rear silencer ⇒ Rep. gr. 26 .
– Remove propshaft ⇒ Running gear; Repair group 39; Re‐
moving and installing propshaft .
– Remove rear axle ⇒ Running gear; Repair group 42; Repair‐
ing rear axle; Removing and installing rear axle .
– Open tank flap.
– Unscrew securing bolt and remove tank flap unit with rubber
cup.
2. Fuel tank 15
Phaeton 2003 ➤
n AG. Volkswagen AG
wage - Diesel engines d-oEdition
Fuel supplyVsystem es n 09.2014
olks gu ot
y
db ara
ise nte
– Unscrew securing
hor bolts for filler neck ⇒ Item 21 (page 9)
eo .
aut ra
c
– Unclip sboth covers for sender flanges in luggage compartment
s
ce
le
floor.
un
pt
an
d
itte
y li
– Pull connectors -arrows- off right sender flange.
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
– Pull connectors and supply hose -arrows- off left sender
atio
flange. When doing this, wrap a cloth around supply hose.
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.
– Unbolt cross piece -1-.

– Support fuel tank with engine and gearbox jack - V.A.G 1383
A- .
– Loosen tensioning straps -2-.
– Lower fuel tank.
Installing
Installation is carried out in the reverse order. When installing,
note the following:
♦ Connections for breather and fuel lines must engage audibly
when joined.
♦ Do not interchange supply line and return line (return line blue
or with blue marking, supply line black).
♦ Install breather and fuel hoses free of kinks.
♦ Secure fuel hoses with spring-type clips.
♦ Ensure that fuel hose connections are tight.
Note
Before raising fuel tank, check that the supply, return and breather
lines are still clipped onto the fuel tank.
2.3 Emptying fuel tank

Special tools and workshop equipment required

Phaeton 2003 ➤
♦ Fuel extractor - VAS 5190-
♦ Fuel tank sender unit tool - 3087-
WARNING
Fuel supply lines are under pressure! agen Before loosening doehose
AG. Vo agen AG lksw
ksw s no
connections, wrap a cloth around
by V the connection. Then release
ol t gu
pressure by carefully pulling
ris
e hose off connection.
d ara
nte
tho eo
s au ra
c
s
Procedure
ce
le
un
pt
an
d
itte

y li
rm
ab
pe
ility
– Open tank flap.

ot
wit
, is n
– Insert suction hose -arrow- of fuel extractor - VAS 5190- ap‐

h re
hole
prox. 160 … 170 cm into fuel filler neck.

spec
es, in part or in w
– Extract fuel.
t to the co
When no more fuel can be extracted

rrectness of i
– Unclip both covers for sender flanges in luggage compartment

floor.
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 tank 17
Phaeton 2003 ➤
– Pull connectors -arrows- off right sender flange.
– Pull connectors and supply hose -arrows- off left sender

flange. Separate plug-in connectors ⇒ page 25 .
– Wrap a cloth around fuel hose for auxiliary heater on left send‐
er flange, and pull off fuel hose.
– Using fuel tank sender unit tool - 3087- , pull locking ring off
left and right sender flanges.
– Lever off sender flanges and remove them.
– Insert suction hose of fuel extractor - VAS 5190- as deeply as
possible into right and then left side of fuel tank.
– Extract fuel.
For further work on inside of fuel tank, sender flanges may remain
removed.
If fuel tank only needs to be drained, reinstall sender flanges.
– Ensure that seals of sender flanges are seated correctly.
Note
AG. Volkswagen AG d
agen oes
lksw not
Renew seals if the fueld bhas
y V caused them to swell.
o gu
ara
ise nte
or eo
h
aut ra
– Insert sender
s flanges with marking pointing in direction of trav‐ c
s
ce
le
el -arrow-.
un
pt
an
d
itte
– Tighten locking rings on right and left using fuel tank sender
y li
erm
ab
unit tool - 3087- .

ility
ot p
wit
is n
h re
ole,
spec
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Phaeton 2003 ➤
3 Fuel delivery unit, fuel gauge sender

⇒ “3.1 Removing and installing fuel delivery unit, fuel gauge send‐
er”, page 19
3.1 Removing and installing fuel delivery

unit, fuel gauge sender
⇒ “3.1.1 Removing and installing fuel pump 1 V276 , fuel gauge
sender and suction-jet pump on right side”, page 19
⇒ “3.1.2 Removing and installing fuel pump 2 V277 , fuel gauge
sender and suction-jet pump on left side”, page 22
3.1.1 Removing and installing fuel pump 1 -

V276- , fuel gauge sender and suction-
jet pump on right side
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
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
Test prerequisites
t to the co
• Connectors and wires for left and right-hand sender flanges
have been removed.
rrectne
• Locking rings for left and right sender flanges have been re‐
moved.
ss o
cial p
• Fuel pump relays have been removed from fuse box.

inform
mer
Procedure
atio
om

c
i
or
n thi
te
– Release and pull off 3 connectors -arrows- below right sender

sd
iva
o
r
flange.
p
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Fuel delivery unit, fuel gauge sender 19

Phaeton 2003 ➤
– On right-hand side -B-, unclip fuel gauge sender (plunger-

type) -3- from fuel pump -1- -arrows- and carefully pull it out.
– Pull black filler hose out of opening -4- in fuel pump housing
-1-.
– On right-hand side -B-, pull return hose of left suction-jet pump
-2- from fuel pump -1- -arrows-.
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
wit
, is n
h re
hole
spec
– On right-hand side, pull off return line -1- and supply line -2-.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
– Release and pull off 3 connectors -arrows- below left sender

f
en
ng
t.
flange. Cop
yi Co
py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– On left-hand side, pull supply hose -1- off Y-piece -2-.

– Then, pull out supply hose through hole for right sender.

Phaeton 2003 ➤
– Push both retaining clips -1- of right fuel pump -B- slightly to
one side.
– Carefully remove pump.
Note
The fuel pump housing is filled with fuel. Fuel may run out if hous‐
ing is tipped or canted.
– On left-hand side -A-, unclip black return hose -2- from fuel
pump housing -1- -arrows-. olkswage es n
o
yV t gu
db ara
rise 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
l purpos
nform
ercia
– Pull supply hose -3- off Y-piece -2-. Then, pull out both suction-
m
at
jet pump hoses through hole for right sender.

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.

Phaeton 2003 ➤
– Unclip suction-jet pump -3- on right side -B- and remove it by

turning slightly.
– Unclip and pull out fuel gauge sender -2-.
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
, is n
h re
hole
3.1.2 Removing and installing fuel pump 2 -
spec
es, in part or in w
V277- , fuel gauge sender and suction-
t to the co
jet pump on left side
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.
Test prerequisites
• Connectors and wires for left and right-hand sender flanges
have been removed.
• Locking rings for left and right sender flanges have been re‐
moved.
• Fuel pump relays have been removed from fuse box.
Procedure

Phaeton 2003 ➤
– Release and pull off 3 connectors -arrows- below left sender

flange.
– On left-hand side -A-, unclip fuel gauge sender (plunger-type)

-3- from fuel pump -1- -arrows- and carefully pull it out.
– On left-hand side -A-, unclip return hose of right suction-jet
pump -2- from fuel pump -1-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
– Release and pull off 3 connectors -arrows- below right sender

un
pt
an
d
flange.
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
– On right-hand side, pull off return line -3- and supply line -4-.
inform
mer
– Pull out both hose ends through hole for left sender.
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
cted agen
Prote AG.

Phaeton 2003 ➤
– Push both retaining clips -1- of left fuel pump -A- slightly to one
side.
– Carefully remove fuel delivery unit with sender flange connec‐
ted.
Note
wage es n
The fuel pump housing is filled with fuel. yFuel
Vol may run out if hous‐
ks ot g
ing is tipped or canted. ise
d b ua
ran
tee
r
ho
aut or
ac
ss
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
– On right-hand side -B-, unclip black return hose -2- from fuel
pump housing -1- -arrows-.
rrectness of i
– Pull out black filler hose of suction-jet pump through hole for
left sender.
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.
– On left-hand side -A-, unclip suction-jet pump -3- and remove

it by turning slightly.
– Unclip and pull out fuel gauge sender -2-.
Note
Now, only two fuel lines (supply ⇒ Item 19 (page 11) and return
⇒ Item 19 (page 11) ) can be seen through the hole for right send‐
er. These can only be removed via the supply and return flange
⇒ Item 9 (page 10) with fuel tank removed.

Phaeton 2003 ➤
4 Push-on connectors
⇒ “4.1 Detaching push-on couplings”, page 25
4.1 Detaching push-on couplings

gen AG
. Volkswagen AG
wa does
olks not
♦ Lever - T10468- byV gu
ara
ed nte
ris
tho eo
au ra
c
ss
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
Assignment of push-on couplings
l purpos
Note
nform
ercia
The push-on couplings for fuel, vacuum and breather lines are
m
a
com
colour coded. There is either a coloured dot on the connector or
tion in
the release button is coloured.
r
te o
thi
s
iva
do
r
Push-on coupling Colour code on connector

rp
cum
fo
en
ng
Fuel supply Black

t.
yi Co
Cop py
Fuel return line Blue
t. rig
gh ht
pyri by
Breather White
co Vo
by lksw
cted agen
Prote
Vacuum Green
AG.
WARNING
Fuel supply line is pressurised. Wear eye protection and pro‐

tective clothing to avoid eye injuries and skin contact. Before
loosening hose connections, wrap a cloth around the connec‐
tion. Then release pressure by carefully pulling hose off con‐
nection.
Variant 1
Plug-in connector with release buttons -arrows- on right and left.
4. Push-on connectors 25
Phaeton 2003 ➤
Opening
It is necessary to counterhold the separating point for fuel -1-.
– Insert -T10468- between heat shield and stop -arrow- of fuel
line -2- and counterhold.
Continuation for all separating points on fuel system

– Push push-on coupling -1- in -direction of arrow A-.
– Press and hold release buttons.
– Pull push-on coupling -1- off fuel line -2- in
-direction of arrow B-.
Take note of colour assignment during installation ⇒ page 25
– Ensure plug-in connector is securedagproperly
en AG. V by pulling
olkswagen AG it.
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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Variant 2
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Plug-in connector with pull-release mechanism -arrow-.

rrectness of i
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Phaeton 2003 ➤
Opening
– Push push-on coupling -1- in -direction of arrow A-.
– Pull pull-release mechanism -2- in -direction of arrow B-.
– Pull push-on coupling -1- off fuel line -3- in
-direction of arrow B-.
– Ensure plug-in connector is secured properly by pulling it.
Variant 3
Plug-in connector with front button -arrow-.
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Opening y Volks not
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– Press releasehobutton
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Take note ofscolour assignment during installation ⇒ page 25 c
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pt
– Ensure push-fit couplings are secured properly by pulling.

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Variant 4
es, in part or in w
t to the co
Push-on coupling with release buttons -arrows- on right and left

Opening
rrectness of i
– Press push-on coupling in -direction of arrow A-.

l purpos
– Press release buttons -arrows- and pull push-on coupling off.

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Variant 5
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Push-on coupling with release buttons -arrows- on right and left t. Cop py
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Take note of colour assignment during installation ⇒ page 25 Prote AG.
– Press release buttons -arrows- and pull push-on coupling off.

4. Push-on connectors 27
Phaeton 2003 ➤
Fuel supply system - Diesel engines - eEdition 09.2014
n AG. Volkswagen AG ag does
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Push-on coupling with release abuttons
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-arrows- on right and left ra
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Opening
ce
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– Push push-on coupling in -direction of arrow-.
itte
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pe
– Press and hold release buttons -arrows-.
ility
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– Pull off push-on coupling
h re
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es, in part or in w
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rrectness of i
Variant 7
l purpos
Opening
– Press push-on coupling onto fuel pipe until catch -A- is at stop.
nform
ercia
– Hold catch in this position and carefully pull push-on coupling

m
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off.
com
tion in
Take note of colour assignment during installation ⇒ page 25 .
r
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Cop py
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pyri by
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Prote AG.

Phaeton 2003 ➤
5 Fuel cooler
⇒ “5.1 Removing and installing fuel cooler”, page 29
5.1 Removing and installing fuel cooler

Removing
– Remove upper part of cover -1-.
– Pull off quick-release catches -2-. Catch any escaping fuel.
Separate plug-in connectors ⇒ page 25 .
– Loosen securing nuts -arrows-, and remove fuel cooler.
Installing
Install in reverse order. In the process, note the following:
♦ Tighten securing nuts for fuel cooler to 15 Nm.
AG. Volkswagen AG d
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5. Fuel cooler 29
Phaeton 2003 ➤
6 Fuel filter
⇒ “6.1 Assembly overview - fuel filter”, page 30
⇒ “6.2 Removing and installing fuel filter”, page 33
⇒ “6.3 Fuel hoses in engine compartment, engine code AJS”,
page 34
6.1 Assembly overview - fuel filter

⇒ “6.1.1 Assembly overview - fuel filter, engine codes BMK,
CARA, CEXA, CEXB”, page 30
Volkswa
⇒ “6.1.2 Assembly overview - fuelwafilter,
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AJS”,
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6.1.1 Assembly overview - fuel filter, engine codes BMK, CARA, CEXA, CEXB
ee t
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1 - Supply line
an
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❑ From fuel tank
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⇒ Item 18 (page 9) .
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❑ White marking
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2 - 5 Nm
3 - Return line
rrectne
❑ To fuel cooler.
ss
ing.
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❑ Blue or with blue mark‐

form
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4 - Plug for water extraction

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❑ Remove and extract

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about 100 cm3 liquid us‐

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uum pump with acces‐

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op
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and water drainage con‐ gh ht
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tainer - V.A.G 1390/1- . cop Vo
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5 - Seal
❑ Renew.
6 - Supply line
❑ For engine codes
CARA, CEXA, CEXB: to
supplementary fuel
pump - V393-
⇒ page 56
7 - Return line
❑ From high-pressure
pump.
ing.
❑ Check for secure seating.

Phaeton 2003 ➤
8 - Upper part of fuel filter

9 - Fuel temperature sender - G81-
10 - Seal n AG. Volkswagen AG do
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❑ Renew. d byV ua
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11 - Filter insert autho
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12 - Seal
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❑ Renew.
an
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13 - Lower part of fuel filter
ility
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14 - Seal
is n
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ole,
❑ Renew.
spec
15 - Retaining clip
t to the co
16 - Connection
17 - To high-pressure pump.
rrectness o
6.1.2 Assembly overview - fuel filter, engine code AJS
cial p
f inform
mer
Fuel hose schematic diagram ⇒ page 34 .
atio
om
n
c
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or
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1 - 8 Nm
thi
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2 - Fuel filter cover
pr
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❑ Fuel hose connection
en
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t.
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⇒ page 32 t. Cop py
rig
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3 - Seal yri
p by
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❑ Renew. cted agen
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4 - Fuel filter insert

❑ Observe change inter‐
vals.
5 - Water drainage connection
❑ To drain water, extract
approx. 100 cm3 fluid
using diesel extractor -
VAS 5226-
❑ Tighten sealing plug to 3
Nm
6 - Return line
❑ To fuel tank.
ing.
ing.
7 - Supply
❑ From fuel tank.
❑ White or with white
marking.
ing.
6. Fuel filter 31
Phaeton 2003 ➤
8 - Coolant return line

9 - Coolant supply line
10 - 8 Nm
11 - 3 Nm
12 - Fuel composition sender - G133-
❑ Renew O-ring.
13 - Fuel filter housing
Fuel hose connection

– Renew seal between connecting piece and fuel filter cover.
– Tighten securing bolts -arrows- to 8 Nm.
olkswagen AG
en AG. V
– If necessary, seal connecting piece ksfor
wagfuel hoses with sealing
does
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tool - T10247- . ed
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Phaeton 2003 ➤
6.2 Removing and installing fuel filter

⇒ “6.2.1 Removing and installing fuel filter, engine code AJS”,
page 33
6.2.1 Removing and installing

Volkswa
fuel filter, engine code AJS
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Special tools and rworkshop
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♦ Hose clip pliers - V.A.G
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1921- or spring-type clip pli‐
ility
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♦ Hand vacuum pump -
hole
spec
V.A.G 1390- and venting
es, in part or in w
container - V.A.G 1390/1-
t to the co
or diesel extractor - VAS
5226-
rrectness of i
♦ Not illustrated: hose
clamps, up to Ø 25 mm -
l purpos
3094- .
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Removing
– Connect hand vacuum pump -V.A.G 1390- with bleeder bottle
-V.A.G 1390/1- to water drain plug of fuel filter.
– Operate hand vacuum pump until no more fuel comes out. Be
careful that no fuel is sucked into hand vacuum pump.
6. Fuel filter 33
Phaeton 2003 ➤
– Unscrew both securing bolts -1-, and remove connecting piece

with fuel lines.
– Pull supply hose -3- (white marking) and return hose -2- (blue
marking) off fuel filter.
– Open filler cap on coolant expansion tank.
– Clamp off both coolant hoses -4- with hose clamps, up to Ø
25 mm - 3094- .
– Pull off coolant hoses and collect escaping coolant with a cloth.
– Unscrew both securing bolts -arrows-, and pull fuel filter slight‐
ly towards front.
– Unclip lines on rear of fuel filter. AG. Volkswagen AG d
agen oes
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– Release and pull off connector forbyfuel
Vol composition sender - not
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– Remove fuel filter. ss au ra
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Installing
nl
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note the following:
ility
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– Renew seal between connecting piece and fuel filter cover.
, is n
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hole
– Tighten plug for water drainage connection to 3 Nm
spec
es, in part or in w
– Replenish coolant ⇒ Rep. gr. 19 ; Draining and filling with
t to the co
coolant .
6.3 Fuel hoses in engine compartment, engine code AJS rrectness of i

l purpos
nform
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ion
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ate
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Prote AG.

Phaeton 2003 ➤
1 - Return line
❑ To fuel tank.
ing
ing.
2 - Supply line
❑ From fuel tank.
❑ White or with white
marking
ing.
3 - Fuel rail
❑ For cylinder bank 2.
wage
4 - Test connection olks es n
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❑ For cylinder bank 1. ir se
d ran
tee
ho
❑ Tighten sealing plug to aut or
ac
27 Nm ss
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pt
❑ Not necessarily instal‐
du
an
itte
led
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erm
ab
ility
5 - Fuel rail
ot p
wit
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hole
spec
6 - Tandem pump
es, in part or in w
t to the co
❑ With vacuum pump
7 - Fuel temperature sender -
rrectness of i
G81-
l purpos

8 - Fuel filter
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9 - Fuel pump
m
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atio
m

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10 - Fuel temperature sender 2 - G248-
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11 - Test connection
t.
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❑ For cylinder bank 2. t. C rig
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❑ Tighten sealing plug to 27 Nm cop Vo
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❑ Not necessarily installed Prote AG.
6. Fuel filter 35
Phaeton 2003 ➤
7 Accelerator mechanism
⇒ “7.1 Assembly overview - accelerator module”, page 36
7.1 Assembly overview - accelerator module
1 - Bearing bracket
2 - Connector
❑ Black, 6-pin.
3 - 10 Nm
4 - Accelerator pedal position
sender -G79-
❑ Not adjustable.
❑ Remove footwell cover
to remove sender.
AG. Volkswagen AG d
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d by ara
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nl
pt
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
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ion
c
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or
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t. rig
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by c lksw
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Prote
36
AG.
Rep. gr.20 - Fuel supply system
Phaeton 2003 ➤
8 Fuel pump
⇒ “8.1 Checking fuel pump”, page 37
⇒ “8.2 Removing and installing fuel pump”, page 54
⇒ “8.3 Assembly overview - supplementary fuel pump V393 , en‐
gine codes CARA, CEXA, CEXB”, page 56
8.1 Checking fuel pump

⇒ “8.1.1 Checking fuel pressure of fuel pumps V276 / V277 ”, page
37
⇒ “8.1.2 Checking fuel pressure of supplementary fuel pump
V393 ”, page 45
⇒ “8.1.3 Checking fuel delivery rate of supplementary fuel pump
V393 ”, page 48
⇒ “8.1.4 Checking tandem pump and fuel pump, engine code
AJS”, page 52
8.1.1 Checking fuel pressure of fuel pumps -

V276- / -V277-
♦ Pressure gauge - VAS 6551-
AG. Volkswagen AG d
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ab
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♦ Adapter set - VAS 6551/5-

wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
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at
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ion
c
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or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
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by c lksw
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Prote AG.
8. Fuel pump 37
Phaeton 2003 ➤
♦ Removal wedge - 3409-
♦ Hose clip pliers - V.A.G 1921-
♦ Vehicle diagnosis and service information system

♦ Fuel hose, commercially available - 7,5 mm x 3 mm-olkswage es n
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yV ua
db ran
rise tee
WARNING tho or
au ac
ss
ce
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nl
pt
du
ing of a door with the battery connected. Fuel can escape if the an
itte
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erm
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ility
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Test prerequisites
hole
spec
• Connect battery charger, battery voltage at least 12.5 volts ⇒

es, in part or in w
Electrical system; Rep. gr. 27 ; Battery; Charging battery .

t to the co
• Fuses OK. ⇒ Current flow diagrams, Electrical fault finding and

Fitting locations.
rrectness of i
• Event memory OK ⇒ Vehicle diagnostic tester.

l purpos
• Fuel filter OK.

nf
ercia
• Ensure that vehicle is placed on a level surface.

orm
m
atio
• Fuel tank at least 1/2 full.

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

thi
te
sd
a
must be switched off.

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Cop py
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rig ht
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by lksw
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Prote AG.

Phaeton 2003 ➤
Note
♦ The vehicle must be fuelled with the diesel fuel appropriate for
the time of the year. Summer diesel fuel may coagulate (flock)
at low winter temperatures.
♦ Diesel fuel sold in the summer is guaranteed to be capable of
filtration down to 0°C.
♦ Diesel fuel sold in the summer/winter transition is guaranteed
to be capable of filtration down to -10°C.
♦ Diesel fuel sold in the winter is guaranteed to be capable of
filtration down to -20°C.
♦ Test sample, if unsure in winter.
♦ Expose sample to low ambient temperature for approx. 1 hour.
♦ If the fuel coagulates (flocks) at temperatures down to -20°C,
it is unsuitable for low temperatures. This coagulation may
block the strainer in the fuel delivery unit as well as the fuel
filter.
Test procedure
– Observe rules for cleanliness ⇒ page 4 .
– Switch off ignition.
– Remove engine cover panel ⇒ Rep. gr. 10 ; Engine cover;
Removing and installing Aengine cover
G. Volkswagen panel .
gen AG do
swa es
– Remove intake y Vhose and air filter upper part ⇒t gRep.
olk no
ua gr. 23 ;
Diesel directed binjection system; Assembly overview ra-n air filter .
ris t ee
tho o
– Detach au clip -arrow- and pull fuel supply line -1- off supplemen‐
ra
c
ss
tary fuel pump - V393- -2-.
ce
e
nl
pt
du
an
itte
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WARNING
erm
ab
ility
ot p
The fuel line is under pressure.

wit
, is n
h re
hole
Risk of injury to eyes and skin from fuel.

spec
es, in part or in w
Wear eye protection and protective clothing to avoid eye inju‐

t to the co
ries and skin contact. Before loosening hose connections,

wrap a cloth around the connection. Then release pressure by
carefully opening the connection point.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
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by lksw
cted agen
Prote AG.
8. Fuel pump 39
AG. Volkswagen AG d
Phaeton 2003 ➤ agen oes
ksw not
Vol
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– Fit hose - VAS 6551/1- into fuel supply line -2- and secure
ss
au
it ra
c
with clip.
ce
le
un
pt
an
– Connect hose - VAS 6551/1- to connector -A- of pressure
d
itte
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tester (diesel) - VAS 6551- .
rm
ab
pe
ility
– Connect standard hose -3- to connection -B- of pressure tester
ot
wit
, is n
(diesel) - VAS 6551- and secure it with clip.
h re
hole
spec
– Connect standard hose -3- to supplementary fuel pump -
es, in part or in w
V393- -1 - and secure it with a clip.
t to the co
– Switch on pressure tester - VAS 6551- by pressing On/Off
button.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
– Ensure that drain tap -C- on pressure tester - VAS 6551- -1-
r
rp
cum
is closed.
fo
en
ng
t.
yi Co
– Shut-off valves -A- and -B- on pressure tester - VAS 6551- Cop py
t. rig
-1- are open. opyri
gh by
Vo
ht
c lksw
– Connect vehicle diagnostic tester .
by
cted agen
Prote AG.
– Select Vehicle self-diagnosis .
– Select 01 - Engine .
– Select Final control diagnosis .
– Press button ► repeatedly until Fuel pump relay - J17 is
shown on display.
– Start diagnosis by pressing button ► .
Note
The fuel pump will now be activated. During this, the fuel pump
will be switched on and off several times.
– Read off fuel pressure on pressure gauge - VAS 6551- .

• Specification is min. 0.3 bar.
– End diagnosis by pressing button ► .
If the specification is not attained:
– Check fuel lines in engine compartment for possible restric‐
tions (kinks), blockages and damages.
– Check fuel lines in engine compartment for leaks.
– Repeat check ⇒ page 39 .
If the specifications are still not attained:
– Check fuel pressure ahead of fuel filter ⇒ page 42 .

Phaeton 2003 ➤
Checking fuel pressure of fuel pump 1 - V276- :
Note
With this procedure, the fuel pump 1 - V276- will be checked in‐
dividually.
– Remove floor covering from luggage compartment.

– If fitted, pull out pins -arrows-, and remove cover for flange on
right in luggage compartment floor -A-.
– Unclip cover for flange on left in luggage compartment floor.
– Check that connector -1- is fitted securely by pulling connector

without pressing catch. The connector can cause a fault if it
has not been fitted correctly.
– Release and pull off connector -1- for fuel pump 2 - V277-
-2- ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations.
– Check contacts on plug and on fuel delivery unit for damage.
– Repeat fuel pressure test ⇒ page 39 .
– Read off fuel pressure on pressure
agen gauge - VAS 6551-
AG. Volkswagen AG do .
w es n
olks ot g
• Specification is min. 0.25
ed
by bar.
V ua
ran
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If the specification is
au
thnot attained: or
ac
ss
– Remove fuel pump 1 - V276- ⇒ page 19 .
ce
e
nl
pt
du
an
– Check filter strainer for soiling.

itte
y li
erm
ab
– Ensure that all fuel hoses are connected correctly.

ility
ot p
wit
, is n
– Check if all electrical wires are connected correctly.

h re
hole
If no fault is detected:
spec
es, in part or in w
t to the co
– Renew fuel pump 1 - V276- ⇒ page 19 .

If specification is attained:
rrectness of i
Fuel pressure of fuel pump 2 - V277- needs to be checked. To do

this, follow the procedure described below.
l purpos
Checking fuel pressure of fuel pump 2 - V277- :

nform
mercia
at
om
Note
ion
c
in t
or
his
e
With this procedure, the fuel pump 2 - V277- will be checked in‐
at
do
riv
dividually.
p
cum
for
en
ng
t.
yi Co
– Remove floor covering from luggage compartment. t. Cop py
rig
gh ht
– If fitted, pull out pins -arrows-, and remove cover for flange on pyri by
Vo
co
right in luggage compartment floor -A-.
by lksw
cted agen
Prote AG.
8. Fuel pump 41
Phaeton 2003 ➤ n AG. Volkswagen AG do
wage es n
yV
o- Edition 09.2014
lks ot g
b ua
ed ran
ris tee
– Check that connector -1- is fitted securely
tho by pulling connector or
au
without pressing catch. The connector
ss can cause a fault if it ac
has not been fitted correctly.
ce
e
nl
pt
du
an
– Release and pull off connector -1- for fuel pump 1 - V276-
itte
y li
erm
-2- ⇒ Current flow diagrams, Electrical fault finding and Fitting
ab
ility
locations.
ot p
wit
, is n
– Check contacts on plug and on fuel delivery unit for damage.
h re
hole
spec
– Repeat fuel pressure test ⇒ page 39 .
es, in part or in w
t to the co
rrectness of i
l purpos
– Remove fuel pump 2 - V277- ⇒ page 22 .

nf
ercia
orm
– Ensure that all fuel hoses are connected correctly.
m
atio
om
n in
– Check if all electrical wires are connected correctly.
or c
thi
te
sd
iva
o
r
rp
cu
– Renew fuel pump 2 - V277- ⇒ page 22 .
o
m
f
en
ng
t.
yi Co
If specification is attained: Cop py
t. rig
gh ht
yri
– Check fuel pressure of supplementary fuel pump - V393- p by
co Vo
lksw
⇒ page 45 .
by
cted agen
Prote AG.
Checking fuel pressure ahead of fuel filter:

– Detach clip -arrow- and pull fuel supply line -1- off fuel filter
-2-.
WARNING


Phaeton 2003 ➤
– Fit hose - VAS 6551/1- into fuel supply line -1- and secure it
with clip.
– Connect hose - VAS 6551/1- to connector -A- of pressure
– Connect standard hose -3- to connection -B- of pressure tester
– Connect standard hose to fuel filter -2-and secure it with clip.
button.
– Ensure that drain tap -C- on pressure tester - VAS 6551- -1-
is closed.
– Shut-off valves -A- and -B- on pressure tester - VAS 6551-
-1- are open.
– Select Vehicle self-diagnosis .
AG. Volkswagen AG d
agen oes
– Select 01 - Engine . olksw not
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d by ara
ise nte
– Select Final control diagnosis . hor eo
aut ra
s c
– Press button ► repeatedly until Fuel pump relay - J17 is s
ce
le
shown on display.
un
pt
an
d
itte
y li
– Start diagnosis by pressing button ► .
rm
ab
pe
ility
ot
wit
, is n
h re
Note
hole
spec
es, in part or in w
t to the co

rrectness of i

l purpos
– End diagnosis with ► .

nform
ercia
m
a
com
Check fuel filter, renew if necessary ⇒ page 30 .

ion in
r
te o

thi
s
iva
do
Fuel pressure at separating point on underbody needs to be

r
rp
cum
fo
checked. To do this, follow the procedure described below.

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
8. Fuel pump 43
Phaeton 2003 ➤
Checking fuel pressure at separating point on underbody:

– Disconnect fuel line -1- from underbody. Separate plug-in con‐
nectors ⇒ page 25 .
– Connect connecting hose - VAS 6551/5-3- to fuel line -1-.

– Connect connection cable - VAS 6551/5-3- to connection -B-
of pressure tester (diesel) - VAS 6551- .
– Connect connecting hose - VAS 6551/5-4- to fuel line -2-.
– Connect hose - VAS 6551/5-4- to connection -A- of pressure
olkswagen AG
en AG. V
– Connect vehicle diagnostic tester . olkswag does
not
V gu
d by ara
– Select Vehicle self-diagnosis
or
ise . nte
h eo
ut ra
– Select 01 - Engine . ss a c
ce
e
nl
– Select Final control diagnosis .

pt
du
an
itte
y li
– Press button ► repeatedly until Fuel pump relay - J17 is
erm
ab
shown on display. ility
ot p
wit
, is n
– Start diagnosis by pressing button ► . h re

hole
spec
es, in part or in w
t to the co
Note
rrectness of i

l purpos

nf
ercia

orm
m
atio
– End diagnosis by pressing button ► .

om
n in
or c
thi
te
sd
iva
– Check fuel lines leading to fuel filter for possible restrictions

o
r
rp
cu
(kinks), blockages and damages.

o
m
f
en
ng
t.
yi Co
– Check fuel lines leading to fuel filter for leaks. . Cop py
rig
ht ht
rig
If the specification is not attained: py by
co Vo
by lksw
cted agen
– Open flanges for fuel pumps ⇒ page 19 . Prote AG.

– Ensure that all fuel hoses in fuel tank are connected correctly.
– Check if all electrical wires in fuel tank are connected correctly.
– Check fuel pump 1 - V276- ⇒ page 41 .
– Check fuel pump 2 - V277- ⇒ page 41 .

Phaeton 2003 ➤
8.1.2 Checking fuel pressure of supplementa‐

ry fuel pump - V393-
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
ho eo
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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
♦ Removal wedge - 3409-

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

♦ Fuel hose, commercially available - 7,5 mm x 3 mm-
8. Fuel pump 45
Phaeton 2003 ➤
WARNING
ing of a door with the battery connected. Fuel can escape if the
Test prerequisites
Fitting locations.
• Fuel filter OK. AG. Volkswagen AG d
agen oes
olksw not
yV gu
• Ensure that vehicle is placed on a leveled b surface. ara
nte
ris
ho eo
• Fuel tank at least 1/2 full. aut ra
c
ss
ce
le

un
pt
an
d

itte
y li
rm
ab
pe
ility
ot
Note
wit
, is n
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hole
spec
♦ The vehicle must be fuelled with the diesel fuel appropriate for
es, in part or in w
the time of the year. Summer diesel fuel may coagulate (flock)
t to the co
at low winter temperatures.
rrectness of i
l purpos

to be capable of filtration down to -10°C. nform
ercia

m
a
com
tio
♦ Test sample, if unsure in winter.

n in
r
te o
thi
♦ Expose sample to low ambient temperature for approx. 1 hour.

s
iva
do
r
rp
♦ If the fuel coagulates (flocks) at temperatures down to -20°C,

um
fo
en
it is unsuitable for low temperatures. This coagulation may

ng
t.
yi Co
block the strainer in the fuel delivery unit as well as the fuel . Cop py
filter.
ht rig
rig ht
py by
co Vo
by lksw
cted agen
Test procedure Prote AG.

Removing and installing engine cover panel .
– Remove intake hose and air filter upper part ⇒ Rep. gr. 23 ;
Diesel direct injection system; Assembly overview - air filter .

Phaeton 2003 ➤
– Detach clip -arrow- and pull fuel supply line -2- off supplemen‐
WARNING

AG. Volkswagen A
– Fit hose - VAS 6551/1- into fuelkssupply
wage
n
line -2- and secure
G do
es n it
with clip. y Vol ot g
ua
db r e an
ris tee
– Connect hose - VASut6551/1-
ho to connection -B- of pressure or
tester (diesel) - VAS
ss a
6551- . ac
ce
le
– Connect standard hose -3- to connection -A- of pressure tester

un
pt
an
d

itte
y li
rm
ab
– Connect standard hose to connection of supplementary fuel
pe
ility
ot
pump - V393- -1- and secure it with a clip.
wit
, is n
h re
hole
spec
button.
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
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rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
8. Fuel pump 47
AG. Volkswagen
Phaeton 2003 ➤ lkswagen AG do
es n
Vo ot g
Fuel supply dsystem
by - Diesel engines - Edition 09.2014
ua
ra
e nte
ris
tho eo
– Open shut-off
s au taps -A- and -B- of pressure tester (diesel) - VAS ra
c
6551- -1-.
s
ce
e
nl
pt
du
– Close shut-off valve -C-.
an
itte
y li
erm
ab
– Connect
ility
ot p
vehicle diagnostic tester .
wit
, is n
h re
– Select Guided Functions .
hole
spec
– Select function Bleed fuel system .
es, in part or in w
t to the co
– Follow instructions on vehicle diagnostic tester .
rrectness of i
Note
l purpos
The fuel pump will now be activated.
nf
ercia
orm
m
atio
om
n in
or c
thi
e
– Exit function by pressing button ► .

t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
– Check fuel lines in engine compartment for possible restric‐ Cop py
t. rig
tions (kinks), blockages and damages. opyri
gh by
Vo
ht
by c
lksw
cted agen
Prote AG.
If no fault is found:
– Check fuel pressure of fuel pumps -V276- / -V277-
⇒ page 37 .
If specification is attained for fuel pumps -V276- / -V277- :
– Renew supplementary fuel pump - V393- ⇒ page 56 .
8.1.3 Checking fuel delivery rate of supple‐

mentary fuel pump - V393-

Phaeton 2003 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
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♦ Removal wedge - 3409- s
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Pressure regulating valve - VAS 6551/6-

♦ Measuring container, capacity at least 3 litres
♦ Fuel hose, commercially available - 7,5 mm x 3 mm-
8. Fuel pump 49
Phaeton 2003 ➤
WARNING
AG. Volkswagen AG d
agen
Bear in mind that the fuel pump olks can be activated due tos open‐
w e n o
ot g
yV
ing of a door with the battery
d b connected. Fuel can escape if the ua
ran
ir se
tho tee
o
au ra
c
ss
ce
le
un
pt
Test prerequisites
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
Fitting locations.
spec
es, in part or in w
t to the co
• Fuel filter OK.
rrectness of i
• Fuel tank at least 1/2 full.
l purpos
• Ensure that vehicle is placed on a level surface.

nform
ercia

m
a
• Fuel pressure of supplementary fuel pump - V393- OK.
com
tion in
⇒ page 45 .
r
te o
thi
s
iva
do
r
rp
Note
um
fo
en
ng
t.
yi Co
op
♦ The vehicle must be fuelled with the diesel fuel appropriate for C py
t. rig
the time of the year. Summer diesel may coagulate (flock) at
gh ht
yri by
low winter temperatures.
cop Vo
by lksw
cted agen
Prote AG.
to be capable of filtration down to -10°C.
♦ Test a sample, if unsure in winter. Expose sample to low am‐
bient temperature for approx. 1 hour. If the fuel coagulates
(flocks) at temperatures down to -20°C, it is unsuitable for low
temperatures. This coagulation may block the strainer in the
fuel delivery unit as well as the fuel filter.

Removing and installing engine cover panel .
– Remove intake hose and air filter upper part ⇒ Rep. gr. 23 ;
Diesel direct injection system; Assembly overview - air filter .

Phaeton 2003 ➤
– Detach clip -arrow- and pull fuel supply line -2- off supplemen‐
wage es n
WARNING
yV
olks ot g
ua
d b ran
e
ris tee
The fuel line
o
auth is under pressure. or
ac
ss
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
– Connect standard hose -2- to connection -A- of pressure tester
– Connect standard hose to connection of supplementary fuel
rrectness of i
pump - V393- -1- and secure it with a clip.
l purpos
– Connect pressure regulating valve - VAS 6551/6- to connec‐

tion -B- of pressure tester - VAS 6551- .
nform
ercia
– Hold end of hose of pressure regulating valve - VAS 6551/6-

m
in measuring container.
a
com
tion in
r
te o
thi
button.
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.
– Open shut-off taps -A- and -B- of pressure tester (diesel) - VAS
6551- -1-.
– Close shut-off valve -C-.
– Select Guided Functions .
– Select function Bleed fuel system .
– Follow instructions on vehicle diagnostic tester .
Note
The fuel pump will now be activated.
8. Fuel pump 51
Phaeton 2003 ➤
– Adjust pressure to 4.0 bar with pressure regulating valve - VAS

6551/6- .
– Set pressure regulating valve - VAS 6551/6- to feed pressure
using adjuster wheel -arrow-.
• Specification: 4.0 bar. agen
AG. Volkswagen AG d
oes
olksw not
V
– From this point on do not move position of adjuster wheel ed by gu
ara
-arrow-. horis nte
eo
aut ra
– Exit function by pressing button ► . ss c
ce
le
un
pt
– Drain measuring container.
an
d
itte
y li
rm
– Repeat function Bleed fuel system .
ab
pe
ility
ot
wit
, is n
h re
Note hole
spec
es, in part or in w
Activate supplementary fuel pump - V393- for 60 seconds.
t to the co
– After 60 seconds, exit function by pressing button ► .
rrectness of i
– Check quantity delivered in measuring container.
l purpos
• Specified minimum delivery rate: 1800 ml/60 s.
nform
ercia
If the minimum delivery rate is not attained:

m
– Check fuel lines in engine compartment for possible restric‐
a
com
tio
tions (kinks), blockages and damages.
n in
r
te o
thi
s
iva
do
r
rp
c
If no fault is found:
um
fo
en
ng
t.
yi
– Renew supplementary fuel pump - V393- ⇒ page 56 .
Co
Cop py
t. rig
gh ht
yri by
8.1.4 Checking tandem pump and fuel pump,
op Vo
by c lksw
cted agen
engine code AJS
Prote AG.
Note
♦ The tandem pump delivers fuel to cylinder bank 1 and gener‐

ates the vacuum for the brake booster.
♦ The fuel pump delivers fuel to cylinder bank 2.
DANGER!
The tandem pump may, under no circumstances, be disman‐

tled as the vacuum part could malfunction. This would result in
the failure of the brake booster.

♦ Torque wrench - V.A.G 1331-
♦ Vehicle diagnosis, testing and information system - VAS
5051A-
♦ Tandem pump tester - VAS 5187-
Test prerequisites
• Coolant temperature must be at least 85 °C.

Phaeton 2003 ➤
• Unit injectors OK.

• Fuel filter and fuel lines must not be blocked.
Procedure for vehicles with test connections
– Connect tandem pump tester - VAS 5187- to test connection
for cylinder bank 1 -1- or to test connection for cylinder bank
2 -2-.
Work procedure for vehicles without test connections:
Volkswagen AG
– Remove fuel filter ⇒ page 33 .swagen AG. does
olk not
yV gu
edb ara
ris 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
l purpos
nform
mercia
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.
8. Fuel pump 53
Phaeton 2003 ➤
– Connect tandem pump tester - VAS 5187- to supply line for

cylinder bank 1 -1- or to supply line for cylinder bank 2 using
adapter from adapter set - VAS 5187/6- .
– Install fuel filter ⇒ page 33 .
Continuation for all vehicles
– Run the engine at idling speed.
– Connect ⇒ Vehicle diagnostic tester.
gen AG
. Volkswagen AG
a does
lksw not
– Select Vehicle self-diagnosis
db
yV
o
. gu
ara
e nte
ris
– Select 01 - uEngine
tho . eo
ra
a c
ss
– Select 08 - Read measured value block .
ce
le
un
pt
an
d
– Select display group 1 and confirm your entry by pressing the

itte
y li
erm
Q button.
ab
ility
ot p
– Read off idling speed in display field 1.
wit
is n
h re
ole,
– Increase speed to 1500 rpm.
spec
– Observe pressure indicated on pressure gauge.
t to the co
• Specification: min. 7.5 bar.
rrectne
Specification: min. 7.5 bar.
– Using a hose clip, clamp off return line between fuel filter and
s
tandem pump.
s o
cial p
f in
– Repeat check.
form
mer
If specification is now obtained:

atio
om
n
c
– Tandem pump is OK. Renew unit injector O-rings ⇒ Rep. gr.

i
or
n thi
23 .
te
sd
iva
o
pr

um
r
fo
en
ng
t.
– Renew tandem pump or fuel pump ⇒ page 54 .
yi Co
Cop py
ht. rig
– Press ← button. rig ht
py by
co Vo
by lksw
– Select 06 - End output . cted agen
Prote AG.
Note
After pressure gauge has been disconnected, tighten supply line

or plug to 27 Nm.
8.2 Removing and installing fuel pump

⇒ “8.2.1 Removing and installing tandem pump and fuel pump,
engine code AJS”, page 54
8.2.1 Removing and installing tandem pump

and fuel pump, engine code AJS

Phaeton 2003 ➤
♦ Torque wrench - V.A.G 1331-
♦ Spring-type clip pliers - VAS 5024A-
Note
The procedure for removing and installing the tandem pump is

. Volkswagen AG
described. The procedure for removing and installing wagethe
n AGfuel does
pump is identical, except for the step of pulling olks not
by V off the vacuum gu
ara
line. orised
nte
th eo
au ra
c
Removing ss
ce
le
un
pt
an
d
itte
y li
DANGER!
rm
ab
pe
ility
ot
The tandem pump may, under no circumstances, be disman‐

wit
, is n
tled as the vacuum part could otherwise malfunction. This

h re
hole
would result in the failure of the brake booster.

spec
es, in part or in w
t to the co
– Remove fuel filter ⇒ page 33 .

rrectness of i
– Remove intake manifold ⇒ Rep. gr. 23 .

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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
8. Fuel pump 55
Phaeton 2003 ➤
– Detach vacuum line -1- of brake booster from tandem pump

-5-.
– Pull off central connector for unit injectors -3-.
– Pull fuel hose -2- off tandem pump -5-.
– Unscrew securing bolts -arrows-.
– Remove tandem pump -5- from cylinder head.
– Pull tandem pump -5- upwards slightly.
– Pull off fuel hose -4-, and remove tandem pump.
Installing
note the following:
Note
♦ Ensure that tandem pump coupling seats properly in cam‐

shaft.
♦ Always renew tandem pump seals.
– Connect fuel line -4- together with new seals to tandem pump
-5-.
– Tighten banjo bolt to 25 Nm.
– Install tandem pump, and tighten securing bolts -arrows- to
specified torque.
♦ Specified torque, M6: 8 Nm.
♦ Specified torque, M8: 20 Nm
– Attach fuel hose -2- and vacuum hose -1- to tandem pump.
– Connect central connector for unit injectors.
AG. Volkswagen AG d
agen oes
– Install fuel filter ⇒ page 33 . olksw not
y V gu
d b ara
– Install intake manifold ⇒ Rep.thgr.
rise 23 . nte
o eo
au ra
– Carry out road test and read
s all event memories⇒ Vehicle di‐
s c
ce
agnostic tester.
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
h re
Disconnecting the central connector for unit injectors causes

hole
faults to be stored. Therefore, read event memory and delete if

spec
necessary.
es, in part or in w
t to the co
8.3 Assembly overview - supplementary

rrectness of i
fuel pump - V393- , engine codes CARA,

l purpos
CEXA, CEXB
nf
ercia
orm
Note
m
atio
om
n in
or c
The supplementary fuel pump - V393- is installed on the side of

thi
te
the fuel filter in the engine compartment.

sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
56
cop Vo
by lksw
Rep. gr.20 - Fuel supply system Prote
cted AG.
agen
Phaeton 2003 ➤
1 - Supplementary fuel pump -

V393-
2 - From fuel filter.
3 - 10 Nm
❑ Bolted to fuel filter
bracket.
4 - To high-pressure pump.
5 - 10 Nm
6 - Connector
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
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
8. Fuel pump 57

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Service Department. Technical Information

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20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

5.1 Removing and installing fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

8.2 Removing and installing fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

2.1 Safety precautions when working on

When doing any repair work, especially in the engine compart‐

providing that motor is not in air flow.

♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!

2 Rep. gr.00 - Technical data

Danger of burning from very hot fuel.

♦ To release pressure in fuel system, place clean cloth

around connection and carefully undo connection.

loosening hose connections, wrap a cloth around the connec‐

3 General repair notes

3.1 Rules for cleanliness

4 Rep. gr.00 - Technical data

20 – Fuel supply system

Irreversible damage to high-pressure components, especially

These instructions are intended to guide you through the individ‐

⇒ “1.1 Step 1 (Engine was started with incorrect fuel)”,

– Remove fuel delivery unit ⇒ page 19 .

– Drain fuel pump reservoir of fuel delivery unit.

ticles in fuel pump reservoir and on preliminary filter.

Metal particles found?

1.2 Step 2 (Engine was not started with in‐

1. Procedure when filling with incorrect fuel 5

– Repeat procedure, if necessary, until fuel tank is completely

1.3 Step 3 (There are metal particles in fuel

♦ High-pressure accumulator (rail) including fuel pressure reg‐

ulating valve - N 276- and fuel pressure sender - G 247- ⇒

Rep. gr. 23 ; Removing and installing high-pressure accumu‐ y li

♦ Injector ⇒ Rep. gr. 23 ; Removing and installing injectors h re

♦ Fuel return lines (leakage oil lines) ⇒ Rep. gr. 23 ; Assembly

overview - fuel system

♦ Fuel filter ⇒ Maintenance ; Booklet ; Fuel filter: Renewing

– Bleed fuel system ⇒ Rep. gr. 23 ; Filling/bleeding/checking

– Perform road test.

1.4 Step 4 (There are no metal particles in

fuel delivery unit and fuel tank)

It is only permissible to do the following work when the defec‐

6 Rep. gr.20 - Fuel supply system

⇒ “1.5 Step 5 (There are metal particles in high-pressure

⇒ “1.6 Step 6 (There are no metal particles in high-pressure

– Renew following high-pressure components:

♦ High-pressure accumulator (rail) including fuel pressure reg‐

1.6 Step 6 (There are no metal particles in

1. Procedure when filling with incorrect fuel 7

♦ Spring-type clip pliers - VAS 6362- or hose clip pliers - VAS

⇒ “2 Safety precautions”, page 2

⇒ “2.1.1 Assembly overview - fuel tank”, page 8

⇒ “2.1.2 Assembly overview - components on right-hand side in

fuel tank”, page 10

⇒ “2.1.3 Assembly overview - components on left-hand side in

fuel tank”, page 12

⇒ “2.1.4 Schematic diagram of fuel lines and components in fuel

8 Rep. gr.20 - Fuel supply system

❑ Check for secure seat‐

8 - Aperture for left sender

10 - Aperture for supply and