D3E8047B900-Fuel Supply System Petrol Engines

Service
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Passat CC 2009 ➤
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Fuel supply system, petrol 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
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careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
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safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
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matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2019 Volkswagen AG, Wolfsburg D3E8047B900

Passat CC 2009 ➤
Fuel supply system, petrol engines - Edition 05.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . G
. ..V.ol.ks.w.ag.e.n . . . . . . . . . . . . . . . . . . . . . . 1
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1 Safety information . . . . . . . . . . . . .Vo. lk. s.w.a . . . .
......... . . . . . . . . . . . . o.e.s n. o.t g. . . . . . . . . . 1
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1.1 Safety regulations for working on ed fuel supply ......... . . . . . . . . . . . . . . . . . . .ar.an. t . . . . . . 1
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1.2 Safety precautions when working utho on vehicles . ........ with a start/stop system . . e.o.r a. . . 1
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1.3 Safety precautions when susing testers and measuring instruments during a road test . . . . c
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2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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2.1 Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
erm
3
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3 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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3.1 Rules for cleanliness when working on auxiliary/supplementary heater and fuel system . . 4
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spec
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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1 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
rrectness of i
1.3 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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2 Fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.1 Removing and installing fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . 17
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2.2 Removing and installing fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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3 Separating plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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4 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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5 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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5.1 Assembly overview – activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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5.2 Checking fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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6 Accelerator pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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6.1 Assembly overview - accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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6.2 Removing and installing accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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7 Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.1 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Contents i
Passat CC 2009 ➤
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ii Contents
Passat CC 2009 ➤
00 – Technical data
1 Safety information
(VRL013022; Edition 05.2019)
⇒ “1.1 Safety regulations for working on fuel supply”, page 1
⇒ “1.3 Safety precautions when using testers and measuring in‐
struments during a road test”, page 1
⇒ “1.2 Safety precautions when working on vehicles with a start/
stop system”, page 1
1.1 Safety regulations for working on fuel supply

Risk of injury from highly pressurised fuel.
The fuel system is pressurised. Injury from fuel spray possible.
Before opening the fuel system: agen
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– To release pressure, wrap a clean cloth around the connection
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and carefully loosen the connection.
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Danger of fire caused by escaping fuel
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When the battery is connected and the driver door opens, the door
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contact switch activates the fuel pump. Escaping fuel can ignite
and cause a fire.
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– Disconnect voltage supply to fuel pump before opening the
fuel system.
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1.2 Safety precautions when working on vehicles with a start/stop system

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Risk of injury from engine starting unexpectedly

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If the vehicle's start/stop system is activated, the engine can start

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whether the start/stop system is activated.
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– Deactivate start/stop system by switching off the ignition.
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1.3 Safety precautions when using testers and measuring instruments during
a road test
Risk of injury caused by unsecured testing and measuring instru‐
ments
When the front passenger airbag is triggered in an accident, in‐
sufficiently secured testing and measuring instruments become
dangerous projectiles.
– Secure testing and measuring instruments on the rear seat.
1. Safety information 1
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– Have a second person operate the test and measuring equip‐
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2 Rep. gr.00 - Technical data

Passat CC 2009 ➤
2 Identification
⇒ “2.1 Engine number/engine data”, page 3
2.1 Engine number/engine data

Codes CKMA
Exhaust emission standard EU 5
Displacement l 1.4
Power kW 110
RON Bioethanol E85 1) or super un‐
leaded RON 95
1)E85 means that up to 85% bioethanol may be contained in the
fuel. Any mixture ratio below 85% is permissible.
2)In exceptional circumstances min. 95 RON, however with re‐
duced performance.
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agen 2. Identification
Passat CC 2009 ➤
3 General information
⇒ “3.1 Rules for cleanliness when working on auxiliary/supple‐
mentary heater and fuel system”, page 4
3.1 Rules for cleanliness when working on

auxiliary/supplementary heater and fuel
system
When working on the fuel supply and injection system, pay careful
attention to the following “5 rules”:
♦ Thoroughly clean all unions and adjacent areas before dis‐
connecting.
♦ Place removed parts on a clean surface and cover them over.
Use lint-free cloths only.
♦ Carefully cover opened components or seal them if repairs
cannot be carried out immediately.
♦ Install only clean parts; do not remove new parts from pack‐
aging until immediately before installing. Do not use parts that
have been kept unpackaged (for example in toolboxes).
♦ If system is open: do not use compressed air if possible. Try
not to move the vehicle. Volkswa AG. gen AG
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♦ To extract E 85 fuel,
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4 Rep. gr.00 - Technical data

Passat CC 2009 ➤
20 – Fuel supply system

1 Fuel
⇒ “1.1 Assembly overview - fuel tank”, page 5
⇒ “1.2 Removing and installing fuel tank”, page 6
⇒ “1.3 Emptying fuel tank”, page 11
1.1 Assembly overview - fuel tank
Note
♦ Plug-in connectors must engage »audibly« when joined.

♦ Note colour assignment when installing the plug-in connectors
⇒ page 23 .
♦ Ensure plug-in connector is secured properly by pulling it.
♦ Separate plug-in connectors ⇒ page 23 .
1 - Fuel line
❑ Ensure firm seating
2 - Cap
❑ Renew if damaged
3 - Securing bolt
4 - Tank flap unit
❑ With rubber cup.
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6 - Earth connection
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7 - Fuel
❑ Removing and installing
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⇒ “1.2 Removing and in‐

stalling fuel tank”,
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❑ Emptying
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1. Fuel 5
Passat CC 2009 ➤
8 - Securing straps
Note
To secure the securing straps for

the fuel tank, only bolts with loose
washers must be used. This will
stop the securing straps from being
twisted out of position when tighten‐
ing the bolts.
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stop the securing straps from being
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twisted out of position when tighten‐
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12 - Seal
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❑ Renew
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❑ When installing, fit dry in fuel tank opening.

❑ Moisten with fuel only when installing flange.
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13 - Fuel delivery unit

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❑ Removing and installing ⇒ page 17
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❑ Checking fuel pump ⇒ page 34 .
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❑ With fuel gauge sender - G-
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❑ Removing and installing fuel gauge sender - G- ⇒ page 21
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❑ Clean strainer if soiled
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14 - Suction-jet pump gh ht
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15 - Flange with fuel filter Prote
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❑ With 6 bar pressure relief valve

16 - Locking ring
❑ 110 Nm
❑ Remove and install using wrench - T10202- .
1.2 Removing and installing fuel tank

Special tools and workshop equipment required
6 Rep. gr.20 - Fuel supply system

Passat CC 2009 ➤
♦ Torque wrench (5 … 50 Nm) - V.A.G 1331-
♦ Engine and gearbox jack - V.A.G 1383 A-
Removing
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♦ The rear axle must be lowered to remove the fuel tank. s
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♦ Open tank flap and, if necessary, take adapter for wheel lock
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out of luggage compartment before disconnecting battery.
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– Note safety precautions ⇒ page 1 .
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– Check whether a coded radio is fitted. If so, obtain anti-theft spec

code:
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Drain fuel tank with fuel extractor - VAS 5190 A- ⇒ page 11 .

– Remove bench seat ⇒ General body repairs, interior; Rep. gr.
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72 ; Rear seats; Removing and installing bench seat/individual

seats .
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– Remove cover -1- with fuel pump control unit - J538- -2- from
fuel delivery unit.
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1. Fuel 7
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– Release connector -1- and pull off. s
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– Remove right rear wheel.
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– Remove rear right wheel housing liner ⇒ General body re‐
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pairs, exterior; Rep. gr. 66 ; Wheel housing liner; Removing
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and installing wheel housing liner .
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– Pull breather line and pressure retention valve -arrow- off ac‐
tivated charcoal filter. Separate plug-in connectors
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⇒ page 23 . m
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Grasp securing ring (grey) on pressure retention valve and pull
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– Unscrew tank flap unit securing bolt and remove tank flap unit
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⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit;
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Removing and installing tank flap unit .
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– Unbolt filler neck from body -arrows-.
– Unclip wire from filler neck -arrows-.
CAUTION
The fuel system is pressurised.
Danger of injury through fuel spray.
– Wear protective goggles.
– Wear protective gloves.
– To release pressure, wrap a clean cloth around the connec‐
tion and carefully loosen the connection.

Passat CC 2009 ➤
– Separate breather line (white) and fuel line (black) at union.

Separate plug-in connectors
⇒ “3 Separating plug-in connectors”, page 23 .
– Lower rear axle ⇒ Running gear, axles, steering; Rep. gr. 42 ;
Rear axle; Lowering rear axle .
Note
When lowering, ensure sufficient clearance to brake lines and

electrical wiring.
– Unscrew bolts of tensioning straps -arrows-.
Note
Secure fuel tank to prevent it falling down.
– Remove tensioning straps.

– With the help of a 2nd mechanic, lower the fuel tank slowly.
– With the aid of a 2nd mechanic, guide the filler neck out be‐
tween rear axle and body.
Installing
Install in reverse order of removal. Please observe the following:
– With the aid of a 2nd mechanic, guide the filler neck in between
rear axle and body. gen AG
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1. Fuel 9
Passat CC 2009 ➤
– Slowly raise fuel tank into installation position and secure it.
Note
♦ To secure the securing straps for the fuel tank, only bolts with
loose washers must be used. This will stop the securing straps
from being twisted out of position when tightening the bolts.
♦ Plug-in connectors for fuel lines must engage
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Tighten securing bolts -arrows-.
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– Attach rear axle to body again ⇒ Running gear, axles, steer‐
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♦ Install breather lines and fuel lines free of kinks.
♦ Ensure that line connections are tight.
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♦ Check fuel tank/body earth connection on filler neck.
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– Fill fuel tank with at least 5 litres of fuel.
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WARNING
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Risk of explosion of fuel tank caused by fuel pump activation.
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Risk of severe injuries and burns.

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– If a new or completely empty fuel tank has been installed, fill

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it immediately with at least 5 litres of fuel.

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Specified torque
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Component Specified torque
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Tensioning straps to body 25 Nm
♦ Use new bolts.
♦ To secure the securing straps for the fuel tank, only
bolts with loose washers must be used. This will
stop the securing straps from being twisted out of
position when tightening the bolts.
Filler neck to body 8 Nm +90°

Subframe/rear axle to body ⇒ Running gear, axles, steering; Rep. gr. 42 ; Rear
♦ Use new bolts. axle; Removing and installing rear axle .
Fitting wheels ⇒ Running gear, axles, steering; Rep. gr. 44 ; Wheels,

tyres; Specified torques for wheel bolts

Passat CC 2009 ➤
1.3 Emptying fuel tank

⇒ “1.3.1 Emptying fuel tank when fuel pump is intact”,
page 11
⇒ “1.3.2 Emptying fuel tank if it is more than 3/4 full”, page 13
⇒ “1.3.3 Emptying fuel tank if it is less than 3/4 full”, page 14
1.3.1 Emptying fuel tank when fuel pump is intact
Special tools and workshop

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♦ Removal wedge - 3409-

♦ Remote control - V.A.G 1348/3A-
♦ Test instrument adapter/DSO (5-pin) - VAS 5565-
♦ Fuel extractor - VAS 5190-
♦ Fuel extractor - VAS 5190 A- for E 85 fuel (not shown).
♦ Adapter for fuel extraction - VAS 5190-
1. Fuel 11
Passat CC 2009 ➤
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.
CAUTION
– Pull off supply line (metal connector) -1-. Collect escaping fuel
with a cleaning cloth. Separate plug-in connectors
AG. Volkswagen AG d
agen oes
olksw not
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or eo
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un
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ility
ot p
– Connect fuel extractor - VAS 5190- with adapter for fuel ex‐
wit
is n
tractor - VAS 5190 /3- to fuel supply line.
h re
ole,
spec
CAUTION
Risk of fire due to escaping fuel. t to the co
rrectne
– Check all connected lines for secure fit by pulling.

– Take any fuel-soaked cloths away from area of vehicle.
ss o
cial p
f in
– Secure earth wire of fuel extractor to a bare metal part of the

form
mer
body.
atio
om

c
i
or

thi
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seats .
iv
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– Fold back carpet on right in area of fuel delivery unit.

en
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Prote AG.

Passat CC 2009 ➤
– Remove cover -1-.
– Pull off connector -arrow-.
AG. Volkswagen AG d
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ility
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spec
– Connect test instrument adapter/DSO (5-pin) - VAS 5565- to
es, in part or in w
connector and fuel delivery unit.
t to the co
– Connect remote control - V.A.G 1348/3A- to test instrument
adapter/DSO (5-pin) - VAS 5565- and to battery positive +.
rrectness of i
l purpos
Note
nform
ercia
This step serves only to have the fuel pump running when the
engine is stopped.
m
a
com
tion in
– Remove filler cap from fuel tank filler neck.

r
te o
thi
s
iva
– Operate remote control - V.A.G 1348/3A- and shut-off tap on

do
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rp
fuel extractor - VAS 5190- until fuel tank is empty.

um
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op
NOTICE C py
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rig ht
Risk of irreparable damage to fuel pump if allowed to run dry.
py by
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cted
– Never allow fuel pump to run »dry«.
agen
Prote AG.
1.3.2 Emptying fuel tank if it is more than 3/4

full
1. Fuel 13
Passat CC 2009 ➤

– Make a mark -arrow- at distance -a- = 990 mm from end of
extraction hose.
– Use insulating tape for this.
Note
♦ The shaft end -1- and adapter -2- are not used.
♦ There is a flap on the lower end of the fuel filler neck in the fuel
tank which must not be damaged by the extraction hose. You
must therefore push hose into filler
agenneck only as far
AG. Volkswagen AG as
doesmark‐
ing. yV
olksw not
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ed nte
oris
– Secure earth wireaof
ut fuel extractor
h to a bare metal part of the e or
ac
body. ss
ce
e
nl
pt
– Push extraction hose into fuel tank until marking on hose co‐
du
an
itte
incides with filler neck.

y li
erm
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ility
– Drain fuel tank via filler neck as far as possible.

ot p
wit
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– Pull extraction hose out carefully.

h re
hole
spec
es, in part or in w
t to the co
Note
♦ When no more fuel is extracted, the tank is emptied just

rrectness of i
enough for the sender flange to be opened without danger.

The tank may be removed while containing remaining fuel.
l purpos
♦ Draining fuel tank completely

⇒ “1.3.3 Emptying fuel tank if it is less than 3/4 full”,
nform
ercia
page 14
m
at
om
ion
c
in t
r
1.3.3 Emptying fuel tank if it is less than 3/4 full

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Prote AG.

Passat CC 2009 ➤
Fuel supply system,
genpetrol
AG. Voengines
lkswagen A-GEdition 05.2019
d
wa oes
olks not
yV gu
Special tools and workshop ed
b ara
nte
ris
equipment required tho eo
au ra
c
ss
ce
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nl
pt
du
an
itte
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ility
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spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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♦ Special wrench - T10202-
♦ Torque wrench - V.A.G 1332-
Note
♦ Plug-in connectors for fuel lines must engage »audibly« when

joined.
⇒ page 23 .

seats .
1. Fuel 15
Passat CC 2009 ➤
fuel delivery unit.
CAUTION
Danger of injury through fuel spray. AG. Volkswagen AG d
agen oes
– Wear protective goggles. Volksw not
gu
by ara
– Wear protective gloves. rise
d
nte
ho eo
– To release pressure, wrap a clean cloth around
s aut
the connec‐ ra
c
tion and carefully loosen the connection.s
ce
e
nl
pt
du
an
itte
y li
– Secure earth wire of fuel extractor to a bare metal part of the
erm
ab
body.
ility
ot p
wit
, is n
h re
– Release connector -1- and fuel line -2- and pull them off flange
hole
-3-. Separate plug-in connectors
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
e
– Open locking ring using wrench - T10202- .

at
do
priv
cum
– Do not cant key - T10202- and press against locking ring firmly.
for
en
g
If the key slips off, the fuel delivery unit can be damaged.
n
t.
yi Co
Cop py
– Raise flange.
t. rig
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pyri by
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o
– Insert suction hose of fuel extractor - VAS 5190 A- as far as
c by lksw
cted agen
possible into fuel tank. Then extract fuel.
Prote AG.
If fuel tank only needs to be emptied, install flange again.
Specified torque
Locking ring 110 Nm

Passat CC 2009 ➤
2 Fuel delivery unit, fuel gauge sender

⇒ “2.1 Removing and installing fuel delivery unit, fuel gauge send‐
er ”, page 17
⇒ “2.2 Removing and installing fuel gauge sender”, page 21
2.1 Removing and installing fuel Volks delivery
wage es n
ot g
unit, fuel gauge sender
y ua
db ran
ise tee
or h
ut or
Special tools and workshop equipment
ss
a required ac
ce
♦ Special wrench - T10202- e
nl
pt
du
an
itte
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erm
ab
ility
ot p
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
♦ Torque wrench (40 … 200 Nm) - V.A.G 1332-

m
at
om
ion
c
in t
or
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ate
do
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for
en
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Removing
Note
♦ The fuel tank must not be more than 3/4 full. This ensures that
the fill level is below the flange of the fuel delivery unit.
♦ Hose connections are secured with either spring-type or
clamp-type clips.
♦ Always renew crimp-type clips with spring-type clips.
♦ Fuel hoses on engine must be secured with spring-type clips
only. The use of crimp-type or screw-type clips is not permis‐
sible.
♦ Hose clip pliers - VAS 6340- are recommended to install
spring-type clips.
♦ After removing fuel delivery unit, check fuel tank for heavy
soiling and clean if necessary.
♦ Drain fuel tank with fuel extractor - VAS 5190 A- .
2. Fuel delivery unit, fuel gauge sender 17

Passat CC 2009 ➤

seats .
fuel delivery unit.
CAUTION
– Release connector -1- and pull off.

– Release fuel line -2- and pull it off fuel delivery unit flange
Note
♦ Make sure all components are mounted in the correct position.

♦ On vehicles with auxiliary heater, the connector and the fuel
line of the metering pump - V54- must also be disconnected.
– Open locking ring using wrench - T10202- and raise flange

slightly.
wage es n
– Do not cant key - T10202- and press against locking ring firmly. yV
olks ot g
ua
If the key slips off, the fuel delivery unit can be damaged. ir se
d b ran
tee
tho
or
– Take fuel delivery unit flange as far as possible out auof the ac
ss
opening in the fuel tank.
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
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fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat CC 2009 ➤
– Pull seal out of opening.

– Release and separate plug-in connector -2-. Separate plug-in
connectors ⇒ “3 Separating plug-in connectors”, page 23 .
– Release suction line of suction-jet pumpe-arrow-
n AG. Volkand
swagpull
en AGit off.
ag does
ksw not
Vol
– Take delivery unit out of fuel tank
by through the opening. gu
ara
ed nte
ris
tho eo
au ra
Note ss c
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e
nl
pt
du
an
♦ When the delivery unit is replaced, the old delivery unit must
itte
y li
emptied before disposal.
erm
ab
ility
ot p
♦ Observe relevant disposal regulations.
wit
, is n
h re
hole
Installing
spec
es, in part or in w
t to the co
– Renew seal.
– Insert seal for fuel delivery unit dry into opening of fuel tank.
rrectness of i
– Coat inner side of seal with fuel.
l purpos
– When inserting fuel delivery unit, ensure that fuel gauge send‐
er is not bent.
nform
ercia
– Attach suction line of suction-jet pump -arrows- and click in

m
at
place.
om
ion
c
in t
r
– Reconnect plug-in connector -2-.

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Prote AG.
– Push flange -1- onto delivery unit -2-. When doing this, ob‐
serve fitting position of guide pins -arrows-.
Note
Make sure that the hoses are correctly fitted.
2. Fuel delivery unit, fuel gauge sender 19

Passat CC 2009 ➤
– Then pull seal -A- over flange.

– Insert into opening of fuel tank.
– Moisten seal lightly with fuel and push flange into fuel tank.
– 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-.
• -Arrow- points in direction of travel.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
– Start locking ring and tighten using wrench - T10202- . Speci‐
an
d
itte
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fied torque ⇒ Item 16 (page 6) .
erm
ab
ility
ot p
wit
is n
h re
ole,
• Tab -2- on flange must be between lugs -1- and -3- on fuel
spec
tank.
t to the co
• -Arrow- points in direction of travel.
– Tighten sealing flange.
rrectness o
cial p
f in
– Attach connector -1-.
form
mer
– Attach fuel lines -2-. atio

om
n
c
i
or
– Ensure plug-in connector and connector are secured properly

thi
e
by pulling.
t
sd
iva
o
pr
cum
r
Further assembly is performed in the reverse order of removal.

fo
en
ng
Please observe the following.

t.
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cted agen
Prote AG.

Passat CC 2009 ➤
♦ Note installation location of fuel extraction line for auxiliary

heater ⇒ Auxiliary heater; Rep. gr. 82 ; Fuel supply; Installa‐
tion location overview - fuel supply .
♦ The -arrow- on the cover points forwards.
Specified torque
Locking ring 110 Nm
2.2 Removing and installing fuel gauge

sender
⇒ “2.2.1 Removing and installing fuel gauge sender G ”,
page 21
2.2.1 Removing and installing fuel gauge

sender - G-
Removing:
– Remove fuel delivery unit
⇒ “2.1 Removing and installing fuel delivery unit, fuel gauge
sender ”, page 17 .
– Pull fuel gauge sender - G- slightly to side and upwards at the n AG. Volkswagen AG do
same time. o lkswage es n
o
yV t gu
db ara
ir se nte
ho eo
aut ra
ss c
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un
pt
an
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itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– If the sender cannot be released in this way, push the securing

tabs -arrows- to the side slightly.
rrectness of i
– Note colour assignment of cables for re-installation.

l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
21
Prote AG.
2. Fuel delivery unit, fuel gauge sender
Passat CC 2009 ➤
– Release and pull off connectors -1…3- and bend back the
locking hooks of connectors.
Installing:
– Connect connectors -1…3-. Note colour assignment.
wage
– Check connectors are secured properly by pulling. olks es n
ot g
byV ua
ed ran
– Insert fuel gauge sender - G- into guide on fuel hordelivery unit
is tee
and press down until it engages. aut or
ac
ss
– Install fuel delivery unit ⇒ page 19 .
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Specified torque
es, in part or in w
t to the co
Locking ring 110 Nm
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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cu
o
m
f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat CC 2009 ➤
3 Separating plug-in connectors

♦ Lever - T10468-
Assignment of plug-in connectors
Note agen
AG. Volkswagen AG d
oes
olksw not
V gu
by
♦ The plug-in connectors
rised for fuel, vacuum and breather lines
ara
ntare
colour coded.ut There is either a coloured dot on the plug-in e or
o e
h
connector sor
s the release button is coloured.
a ac ce
e
nl

pt
du
an
joined.
itte
y li
erm
ab

ility
ot p
wit
, is n
h re
Plug-in connector Colour code on plug-in connec‐

hole
spec
tor
es, in part or in w
t to the co
Fuel supply black

Fuel return line blue
rrectness of i
Breather White, beige

Vacuum green
l purpos
CAUTION
nf
ercia
orm

m
atio
om

n in
or c
thi

te
sd
iva

r
rp
cu
o
m
f

en
ng
t.
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tion and carefully loosen the connection. t. Cop py
rig
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pyri by
Vo
o
Version 1 by c lksw
cted agen
Prote AG.
Plug-in connector with release buttons -arrows- on right and left
3. Separating plug-in connectors 23

Passat CC 2009 ➤
Open
It is necessary to counterhold separating point for fuel -1- in en‐
gine compartment.
– Insert lever - T10468- between heat shield and stop -arrow- of
fuel line -2- and counterhold.
Continuation for all separating points of the fuel system

– Push plug-in connector -1- in -direction of arrow A-.
– Press and hold release buttons.
– Pull plug-in connector -1- off fuel line -2- in
-direction of arrow B-. en AG. V
olkswagen AG
ag does
lksw not
Note colour assignment during
by
Vo installation ⇒ page 23 . gu
ara
d
ise nte
Plug-in connectors for
ut
hofuel lines must engage
r
»audibly« when eo
joined. ss
a ra
c
ce
e
– Ensure plug-in connector is secured properly by pulling it.

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
Version 2
rrectness of i
Plug-in connector with pull-release mechanism -arrow-

l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
yV gu
ed b Passat
ara CC 2009 ➤
nte
ris
ut
ho Fuel supply system, petrol engines - Edition e o 05.2019
ra
s a c
s
Open
ce
e
nl
pt
du
an
itte
– Push plug-in connector -1- in -direction of arrow A-.
y li
erm
ab
– Pull pull-release mechanism -2- in -direction of arrow B-.
ility
ot p
wit
, is n
– Pull plug-in connector -1- off fuel line -3- in
h re
hole
-direction of arrow B-.
spec
es, in part or in w
Note colour assignment during installation ⇒ page 23 .
t to the co
Plug-in connectors for fuel lines must engage »audibly« when
joined.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
Version 3
en
ng
t.
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op
Plug-in connector with front button -arrow-
C py
ht. rig
rig ht
py by
Open
co Vo
by lksw
cted agen
Prote AG.
– Press release button -arrow- and pull off plug-in connectors.
joined.
Version 4
Open
– Push plug-in connector in -direction of arrow A-.
– Press release buttons -arrows- and pull off plug-in connector.
joined.
Version 5
Open
joined.
3. Separating plug-in connectors 25

Passat CC 2009 ➤
Version 6
Open
– Push plug-in connector -1- in -direction of arrow- and maintain
pressure.
joined.
Version 7
Plug-in connector -1- with release buttons -2- on right and left:
Open
– Press plug-in connector -1- in -direction of arrow A- and main‐
tain pressure.
– Press release button -2- in -direction of arrow B- and pull off
plug-in connector -1-.
Note colour assignment during installation ⇒ page 23 . AG. Volkswagen AG d
agen oes
ksw
Plug-in connectors for fuel lines must engage »audibly« whenby Vol not
gu
ara
joined. rise
d
nte
tho eo
– Ensure plug-in connector is secured properlyssby
a pulling it.
u ra
c
ce
e
nl
pt
CAUTION
du
an
itte
y li
erm
Risk of fire due to escaping fuel.
ab
ility
ot p
wit
, is n
h re
– Check all connected lines for secure fit by pulling.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat CC 2009 ➤
4 Fuel filter
AG. Volkswagen AG d
agen oes
Note olksw not
y V gu
d b ara
rise nte
o
♦ Pressure limiting valve and fuel filter
aut are integrated in flange
h eo
ra
of fuel delivery unit and cannot bes renewed individually.
s c
ce
le
un
pt
♦ Renew flange for fuel delivery unit ⇒ page 17 .
an
d
itte
y li
♦ Plug-in connectors for fuel lines must engage »audibly« when erm
ab
ility
joined.
ot p
wit
is n
h re
ole,
⇒ page 23 .
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
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
4. Fuel filter 27
Passat CC 2009 ➤
5 Activated charcoal filter system

⇒ “1 Safety information”, page 1
⇒ “3.1 Rules for cleanliness when working on auxiliary/supple‐
mentary heater and fuel system”, page 4
⇒ “5.1 Assembly overview – activated charcoal filter system”,
page 28
⇒ “5.2 Checking fuel tank breather”, page 29
5.1 Assembly overview – activated charcoal

filter system
Note

joined.
⇒ page 23 .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat CC 2009 ➤
1 - Activated charcoal filter

❑ Location: in rear right
wheel housing.
2 - Pressure retention valve
with connecting hose
❑ To remove, pull off at se‐
curing ring.
3 - From fuel tank
4 - Breather line
❑ To activated charcoal fil‐
ter solenoid valve 1 -
N80-
❑ Clipped onto fuel tank
5 - Breather line
❑ From activated charcoal
filter
6 - Activated charcoal filter sol‐
enoid valve 1 - N80-
❑ Valve closed with igni‐
tion switched off
❑ When engine is warm,
valve will be activated
(pulsed) by engine con‐
trol unit
7 - Connection hose AG. Volkswagen AG d
agen oes
❑ To intake manifold olksw not
y V gu
d b ara
❑ Check for secure seat‐ orise nte
eo
ing. auth
ra
ss c
8 - Nut
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e
nl
pt
du
an
❑ 10 Nm
itte
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erm
ab
❑ Qty. 2
ility
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, is n
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5.2 Checking fuel tank breather

spec
es, in part or in w
t to the co

♦ Hand operated vacuum pump - VAS 6213-
rrectness of i
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5. Activated charcoal filter system 29

Passat CC 2009 ➤
Note

joined.
⇒ page 23 .
Test conditions
• Ignition must be switched off.
Test sequence
– Pull off breather line -1-; to do this, press in release button.
Separate plug-in connectors ⇒ page 23 .
– Connect hand vacuum pump - VAS 6213- to breather line as

shown.
AG. Volkswagen AG d
agen oes
olksw not
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pt
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– Move slide ring -1- on hand vacuum pump - VAS 6213- to po‐
wit
, is n
sition -A- for vacuum.

h re
hole
spec
– Operate hand vacuum pump - VAS 6213- several times. There

es, in part or in w
must be no development of vacuum.

t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
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Cop py
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30
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Prote AG.
Rep. gr.20 - Fuel supply system
Passat CC 2009 ➤
– Seal breather hole in activated charcoal filter -arrow- and op‐

erate vacuum pump again several times. Vacuum must build
up.
– If vacuum does not build up, renew activated charcoal filter.
AG. Volkswagen AG d
agen oes
olksw not
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t to the co
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cial p
f inform
mer
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Cop py
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by lksw
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Prote AG.
5. Activated charcoal filter system 31

Passat CC 2009 ➤
6 Accelerator pedal
⇒ “6.1 Assembly overview - accelerator module”, page 32
⇒ “6.2 Removing and installing accelerator pedal module”,
page 32
6.1 Assembly overview - accelerator module
1 - Connector
❑ Black, 6-pin.
2 - Accelerator position sender olks
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- G79- and accelerator position by V ua
ed ran
sender 2 - G185- oris tee
th or
❑ Openings -A- for re‐ ss
au ac
lease tool.
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pt
❑ To remove, remove
an
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dash panel cover and
erm
ab
pedal cluster cover.
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❑ Removing and installing
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accelerator pedal mod‐
ole,
ule ⇒ page 32
spec
3 - 10 Nm
t to the co
4 - Cap
rrectness o
cial p
f inform
mer
atio
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6.2 Removing and installing accelerator

pedal module

Passat CC 2009 ➤
♦ Release tool - T10238-
♦ Release tool - T10240- (for right-hand drive)
Procedure
– Remove cover for pedal cluster.
swage es n
– Pull connector off accelerator module. byV
olk ot g
ua
d ran
ir se
– Pull off protective cap in upper area of accelerator
tho module. tee
or
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– Remove securing bolt. ss
ce
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un
pt
– To remove accelerator module, push release tool - T10238-
an
d
itte
(for right-hand drive vehicles release tool - T10240- ) into

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rm
ab
intended openings to stop as shown.
pe
ility
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– Pull out accelerator pedal module vertically. wit

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hole
Install in reverse order of removal.

spec
es, in part or in w
t to the co
rrectness of i
l purpos
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mercia
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tion in
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te o
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6. Accelerator pedal 33
Passat CC 2009 ➤
7 Fuel pump
AG. Volkswagen AG d
⇒ “7.1 Checking fuel pump”, page 34 ksw
agen oes
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7.1 Checking fuel pump d b ara
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⇒ “7.1.1 Checking function and voltage supply”,
ss a
page 34 c
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un
⇒ “7.1.2 Checking fuel pressure”, page 37
pt
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⇒ “7.1.3 Checking holding pressure”, page 39 erm
ab
ility
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⇒ “7.1.4 Checking fuel delivery rate”, page 43
wit
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⇒ “7.1.5 Checking current consumption”, page 51
ole,
spec
7.1.1 Checking function and voltage supply
t to the co
rrectne
ss o
cial p
f inform
mer
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c
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♦ Multimeter, e.g. hand-held multimeter - V.A.G 1526E-
by lksw
cted agen
Prote AG.
♦ Adapter set - V.A.G 1594C-
♦ Vehicle diagnostic tester

Passat CC 2009 ➤
Test conditions:
AG. Volkswagen
• Battery voltage lkswmust be at least 11.5 V.
agen AG do
es If
notnecessary, charge
battery ⇒ d byElectrical system; Rep. gr. 27 ; Battery;
Vo gu
ara Charging
battery
orise. nte
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ut r
• Fuse
ss
a for fuel pump control unit - J538- OK ⇒ Current ac flow di‐
agrams, Electrical fault finding and Fitting locations.
ce
le
un
pt
an
d
• Fuel pump control unit - J538- OK ⇒ Vehicle diagnostic tester.

itte
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ab
Test sequence
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Note
spec
es, in part or in w
t to the co
Function of fuel pump is checked using final control diagnosis.
– Connect vehicle diagnostic tester .
rrectness of i
– Connect diagnosis cable connector to diagnostic connection
l purpos
in driver footwell.
– Switch on ignition.
nform
ercia
– Press one after the other in the display the buttons for Vehicle
m
a
com
ti
self-diagnosis , Engine electronics and Final con-
trol diagnosis . on in
r
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do
The fuel pump must now run slowly up to maximum speed.

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Note C py
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♦ The fuel pump runs very quietly.
c by lksw
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Prote AG.
♦ If the final control diagnosis is carried out several times in suc‐
cession, it may be necessary to start the engine briefly before
repeating the final control diagnosis.
– Switch off ignition.

If fuel pump does not run:
seats .
– Guide carpet out and fold upwards, if fitted.
– 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.
– Pull connector -arrow- from fuel pump control unit - J538- .
– Check contacts on plug and on fuel delivery unit for damage.
7. Fuel pump 35
Passat CC 2009 ➤
– Check voltage supply between contacts -1- and -6- using mul‐
timeter .
• Specification: approx. battery voltage
Voltage supply not OK:
– Locate and eliminate open circuit referring to current flow di‐
agram ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
Voltage supply OK:
– Remove right cover with fuel pump control unit - J538- -2- from
assembly opening above fuel delivery unit.
lkswage es n
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– To do this, unclip right cover -1- at retaining tabs -arrows- using

wit
, is n
h re
removal wedge - 3409- .
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
r
Vehicles with auxiliary heater

o
his
ate
do
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– Remove connector -1- from cover -3-.

p
cum
for
en
g
– Release connectors -1- and pull off.

n
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– Unclip sealing grommet -2- downwards from cover -3-.
t. C rig
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pyri by
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– Guide wiring harness out downwards.
co lksw
by
cted agen
Prote AG.

Passat CC 2009 ➤
. Volkswagen AG
gen AG does
– Release and pull fuel delivery line -2- from flange
Vol
ksw -1-. Separate
a
not
plug-in connectors db
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ise
⇒ “3 Separating plug-in connectors”,horpage 23 . nte
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Continued for all vehicles
rrectne
CAUTION
ss
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form
mer
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n
c
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or
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a

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– Check that connector -1- is fitted securely by pulling connector
Co
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without pressing catch. If connector was not inserted correctly, t. C rig
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repeat functional check of fuel pump. p by
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– Release connector -1- and pull off. Prote AG.

If no fault is detected:
Remove fuel delivery unit for checking
⇒ “2.1 Removing and installing fuel delivery unit, fuel gauge send‐
er ”, page 17 .
– Release fuel line -2- and pull it off fuel delivery unit flange
– Open locking ring using wrench - T10202- .

– Check that electrical wires between flange and fuel pump are
connected.
– Check contacts for damage.
If no cable break can be found:
– Renew fuel delivery unit
7.1.2 Checking fuel pressure

7. Fuel pump 37
Passat CC 2009 ➤
♦ Pressure gauge - VAS 6550-
CAUTION
Danger of injury through fuel spray. AG. Volkswagen AG d
agen oes
– Wear protective goggles. Volksw not
gu
by ara
– Wear protective gloves. rised
nte
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– To release pressure, wrap a clean s autcloth around the connec‐ ra
c
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nl
pt
du
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itte
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– Pull off supply line (metal connector) -1-. Collect escaping fuel
erm
ab
with a cleaning cloth. Separate plug-in connectors
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
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AG. Volkswagen AG d
agen oes
Volksw Passat notCC 2009 ➤
gu
y
Fuel risupply
se
d b
system, petrol engines - Editiona05.2019
ran
tee
ho
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ac
– Connect pressure tester - VAS 6550- to fuelsssupply line with
adapter - VAS 6550/1- and -VAS 6550/2- .
ce
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pt
du
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CAUTION
erm
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– Before testing, check all connected lines for secure fit by
es, in part or in w
pulling.
t to the co
rrectness of i
– Make sure that drain tap is closed and cut-off taps are open.
l purpos
– Actuate fuel pump with final control diagnosis to build up fuel
pressure.
nf
ercia
– Read off fuel pressure on pressure gauge.
orm
m
atio
m
• Specification: 4.0…7.0 bar.

o
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or c
If fuel pressure is OK, check holding pressure
thi
te
sd
⇒ “7.1.3 Checking holding pressure”, page 39 .
iva
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If the specification is exceeded:
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– Pressure limiting valve in fuel delivery unit flange is defective. Cop py
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cted
Note
agen
Prote AG.
Pressure limiting valve and fuel filter are integrated in flange of

fuel delivery unit and cannot be renewed individually.
– Renew flange for fuel delivery unit

If specification is not obtained
– Check fuel lines for possible restrictions (kinks) or blockages.
– Remove fuel delivery unit
sender ”, page 17 and check for contamination.
– Check that all hose connections -arrows- are connected.

If no fault is found:
– Renew fuel delivery unit flange with fuel filter and pressure
limiting valve.
Vehicles with front-wheel drive ⇒ Item 15 (page 6)
– Repeat test.
If reading again does not match specification:
– Fuel pump is defective; renew fuel delivery unit
7.1.3 Checking holding pressure

7. Fuel pump 39
Passat CC 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
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nl
pt
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• Fuel pressure OK and pressure tester - VAS 6550- connected.

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ab
Checking fuel pressure

ility
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⇒ “7.1.2 Checking fuel pressure”, page 37 .

wit
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hole
CAUTION
spec
es, in part or in w

t to the co

rrectness of i
pulling.
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nf
ercia
Test sequence
orm
m

atio
m
pressure.
o
n in
or c
thi
e
– Read off fuel pressure on pressure gauge.

t
sd
iva
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rp
cu
• Specification: 4.0…7.0 bar

o
m
f
en
ng
t.
yi
– Observe pressure drop on pressure gauge. After 10 minutes,
Co
op py
the pressure must not drop by more than 1 bar. t. C rig
gh ht
pyri by
If the pressure drops further:
co Vo
by lksw
cted agen
Prote AG.
pressure.

Passat CC 2009 ➤
– Ensure that drain tap -C- is closed and shut-off taps -A- and
-B- on pressure tester - VAS 6550- -1- are open.
– After pressure has built up, close shut-off tap -B- of pressure
tester immediately. Lever is then at right angle to direction of
flow.
If the pressure drops again (leak on fuel tank side):
Leak must be sought on fuel tank side. To do this, proceed as
follows:
– Check fuel lines in engine compartment for leaks ⇒ Rep. gr.
24 ; Injection system; Assembly overview - fuel system .
If no fault is detected, check holding pressure of fuel delivery unit.
– Proceed as described on ⇒ page 41 to do this.
If the pressure does not drop now (leak on engine side):
Note
Search for leak on engine side. Repeat holding pressure check.

This time, close shut-off tap -A- to check whether leak actually is
on engine side.
– Check holding pressure again, but this time close shut-off tap
-A-.
– If there are leaks on engine side, check the outside of fuel
pipes and high-pressure pump for leaks ⇒ Rep. gr. 24 ; In‐
jection system; Assembly overview - fuel system .
If no fault can be determined, check the injectors for leaks:
– Remove spark plugs ⇒ Rep. gr. 28 ; Ignition system; Assem‐
bly overview - ignition system .
– Open shut-off valves -A- and -B-.
– Actuate fuel pump with final control adiagnosis
gen AG
. Volks.wagen AG
does
olksw not
– Check through spark plug holes ewhether
db
y V
fuel has collected on gu
ara
the piston crown due to a leaking
ho
ris injector. nte
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au ac
Checking residual pressure at
ss flange for delivery unit
ce
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nl
pt

du
an
itte

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erm
ab
seats .
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wit
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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
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t.
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Cop py
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41
by c lksw
cted
7. Fuel pump
agen
Prote AG.
Passat CC 2009 ➤
olkswagen AG
en AG. V
– To do this, unclip rightolkcover
swa -1- at retaining tabs
g doe-arrows-
s no using
removal wedgee-d b3409- .
y V t gu
ara
ris nte
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aut ra
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an
d
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rm
ab
pe
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
ercia

m
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com
tion in
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te o
thi
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en
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t.
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Cop py
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– Release and pull fuel delivery line -2- from flange -1-. Separate
ht
pyri by
Vo
o
plug-in connectors ⇒ page 23 . by c lksw
cted agen
Prote AG.

– Disconnect fuel line -2-. Separate plug-in connectors
⇒ page 23 .

Passat CC 2009 ➤
– Connect pressure tester - VAS 6550- with adapter - VAS

6550/1- and adapter - VAS 6550/2- between fuel supply line
and fuel delivery unit.
♦ VAS 6550/1 between fuel line and shut-off tap -B-
♦ VAS 6550/2 between fuel delivery unit and shut-off tap -A-
CAUTION
pulling.
– Ensure that drain tap -C- is closed and shut-off taps -A- and
-B- on pressure tester - VAS 6550- -1- are open.
pressure. en AG. V
olkswagen AG
ag does
lksw n
– After pressure has built bup,
y V close shut-off tap -B- of pressure
o ot g
ua
tester immediately. Lever
ir se
d
is then at right angle to direction ofrante
o
flow. au
th eo
ra
ss c
– Repeat holding pressure check.
ce
e
nl
pt
du
an
If pressure no longer drops:

itte
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erm
ab
– Check fuel line between engine and fuel tank for leaks.
ility
ot p
wit
, is n
If the pressure drops again:

h re
hole
– Open fuel delivery unit flange

spec
es, in part or in w

t to the co
– Check that all hose connections are connected.
rrectness of i
l purpos
Pressure limiting valve in fuel delivery unit flange or pressure re‐

tention valve in fuel pump is leaking.
nf
ercia
– First renew flange with fuel filter and repeat pressure retention
rm
m
test.
atio
om
n in
c
Leaks still present:

or
thi
te
sd
a

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t.
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Cop py
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7.1.4 Checking fuel delivery rate
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
7. Fuel pump 43
Passat CC 2009 ➤
Special tools and workshop

equipment required
lkswage es n
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byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
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nl
pt
du
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itte
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erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
ercia
♦ Remote control for V.A.G 1348 - V.A.G 1348/3A-

m
at
om
io

n
c
in t
or

his
ate
do
priv

um
for
en
ng
t.
♦ Pressure regulating valve - VAS 6550/4-
yi Co
Cop py
t. rig
gh ht
pyri by
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co lksw
by
cted agen
Prote AG.

Passat CC 2009 ➤
♦ Measuring container, capacity: 3 litres

Test conditions:
• Voltage supply OK ⇒ page 34 .
• Fuel pressure OK ⇒ page 37 .
• Battery voltage must be at least 11.5 V. If necessary, charge
battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Charging
battery .
• Fuse for fuel pump control unit - J538- OK ⇒ Current flow di‐
agrams, Electrical fault finding and Fitting locations.
• Fuel pump control unit - J538- OK ⇒ Vehicle diagnostic tester.
• Fuel pump relay - J17- OK ⇒ Vehicle diagnostic tester
• Fuel pump fuse OK ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations
• Check that connector is fitted securely by pulling connector
without pressing catch. If connector was not inserted correctly,
repeat functional check of fuel pump.
• Filling level in fuel tank above reserve.
Test sequence AG. Volkswagen AG d
agen oes
olksw no
– Remove bench seat ⇒ General d by V body repairs, interior; Rep.tgr.
gu
ara
72 ; Rear seats; Removing
orise and installing bench seat/individual nte
eo
seats . auth
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
ercia
– To do this, unclip right cover -1- at retaining tabs -arrows- using

m
removal wedge - 3409- .

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.
7. Fuel pump 45
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
Passat CC 2009 ➤ oris nte
eo
th
Fuel supply system, petrol sengines - Edition 05.2019
au ra
c
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f in
– Release and pull fuel delivery line -2- from flange -1-. Separate
form
mer
plug-in connectors ⇒ page 23 .
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
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rig ht
py by
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by lksw
cted agen
Prote AG.

– Pull connector -1- off flange -3-.

connector and fuel delivery unit.
– Connect remote control - V.A.G 1348/3A- to adapter - VAS
5565- and to battery positive terminal in engine compartment.
Note
This step serves only to have the fuel pump running when the
engine is stopped.

Passat CC 2009 ➤
– The quantity delivered by the fuel pump depends on the bat‐

tery voltage. Therefore, also connect hand-held multimeter - Volkswagen AG
V.A.G 1526E- to contacts -1- and -5- of adapters - VAS 5565-
swa
.gen AG. does
olk not
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CAUTION ris
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The fuel system is pressurised. 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
– Pull off supply line (metal connector) -1-. Separate plug-in
connectors ⇒ “3 Separating plug-in connectors”, page 23 .
rrectness of i
– Collect escaping fuel with a cleaning cloth.
l purpos
– Using hose - VAS 6550- , connect pressure tester - VAS

6550/2- to fuel supply line coming from fuel tank.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
– Connect hose - VAS 6550/2- to connection -A- of pressure Cop py
tester - VAS 6550- -1-.
t. rig
gh ht
pyri by
Vo
o
– Connect pressure regulator valve - VAS 6550/4- -3- to con‐
by c lksw
cted agen
nection -B- of pressure tester - VAS 6550- .
Prote AG.
– Place measuring container down outside vehicle and ensure

that its base is secure. Use suitable workshop equipment to
do this.
– Hold end of hose of pressure regulating valve in measuring
container. Have a second mechanic hold the measuring con‐
tainer and hose.
– Have a second mechanic ensure that end of hose remains in
measuring container during test.
CAUTION
pulling.
that its base is secure.
– Have a second mechanic ensure that end of hose remains
in measuring container during test and measuring container
does not tip over.
– Ensure plug-in connectors are secure properly by pulling.
7. Fuel pump 47
Passat CC 2009 ➤
– Ensure that drain tap -C- on pressure tester -1- is closed.

– Shut-off valves -A- and -B- on pressure tester -1- are open.
– Press remote control - V.A.G 1348/3A- .
Note
The fuel system pressurisation pump - G6- will be actuated.
– 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.
– Drain measuring container.
– Press remote control for 60 seconds whilst measuring voltage
at fuel pump.
– Compare delivered quantity of fuel with

agen
AGspecification
. Volkswagen AGindicated
does
in chart. Volksw not
g y ua
db ran
Name of axis rise Unit tee
tho or
au ac
Quantity of fuel delivered
ss
cm 3
ce
le
un
pt
Voltage at fuel pump with en‐ Volt

an
d
itte
gine not running and pump run‐

y li
rm
ab
ning.
pe
ility
ot
wit
Reading example:
, is n
h re
hole
During the test a voltage of 10.5 volts is measured. This equates

spec
to a minimum fuel delivery rate of approx. 1200 cm3 in 60 sec‐

es, in part or in w
t to the co
onds.

rrectness of i
– Open tank flap unit.

l purpos
– Clean area around fuel filler neck.

nform
ercia
– Unscrew cap from fuel filler neck -arrow-.

m
– Repeat fuel delivery rate check.

com
tion in
r
If reading matches specification:

te o
thi
s
iva
do
– Check fuel tank breather

r
rp
cum
⇒ “5.2 Checking fuel tank breather”, page 29 .

fo
en
ng
t.
yi Co
If specification is not obtained t. Cop py
rig
gh ht
– Check fuel lines for possible restrictions (kinks) or blockages. pyri by
Vo
co lksw
by
cted
– Check fuel lines for leaks and damage.
agen
Prote AG.
Proceed as follows to check fuel delivery rate at fuel delivery unit:

Passat CC 2009 ➤
AG. Volkswagen AG d
agen oes
lksw not
– Pull supplybyline
V -arrow- off at flange and catch
o gu escaping
ara fuel
with a cloth.
rised
Separate plug-in connectors nte
⇒ “3autSeparating
ho
plug-in connectors”, page 23 . eo
ra
ss c
ce
e
CAUTION
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
– Connect pressure tester - VAS 6550- to flange using hose -
VAS 6550/2- .
l purpos
– Connect hose - VAS 6550/2- to connection -A- of pressure
nform
tester - VAS 6550- .
mercia
– Connect pressure regulator valve - VAS 6550/4- to connection
at
om
io
-B- of pressure tester - VAS 6550- .
n
c
in t
or

his
ate
do
riv
that its base is secure. Use suitable workshop equipment to

p
cum
do this.
for
en
ng
t.
yi
– A second mechanic may be needed to ensure that it is secure.
Co
Cop py
ht. rig
– Hold end of hose of pressure regulating valve in measuring
rig ht
py by
o Vo
container. Have a second mechanic hold the measuring con‐
by c lksw
cted agen
tainer and hose. Prote AG.
CAUTION
pulling.
that its base is secure.
– Have a second mechanic ensure that end of hose remains
in measuring container during test and measuring container
does not tip over.
– Ensure that drain tap -C- on pressure tester -1- is closed.

– Shut-off valves -A- and -B- on pressure tester -1- are open.
– Press remote control - V.A.G 1348/3A- .
Note
The fuel system pressurisation pump - G6- will be actuated.
7. Fuel pump 49
Passat CC 2009 ➤
– 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.
– Drain measuring container.
– Press remote control for 60 seconds whilst measuring voltage
at fuel pump.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
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.

Passat CC 2009 ➤
wage es n
– Compare delivered quantity of fuel with specification indicated
yV
olks ot g
ua
in chart. ise
d b ran
r tee
ho
ut or
Name of axis Unit
ss
a ac
ce
le
Quantity of fuel delivered cm 3
un
pt
an
d
itte
Voltage at fuel pump with en‐ Volt
y li
rm
ab
gine not running and pump run‐
pe
ility
ning.
ot
wit
, is n
h re
Reading example:
hole
spec
es, in part or in w
During the test a voltage of 10.5 volts is measured. This equates
t to the co
to a minimum fuel delivery rate of approx. 1200 cm3 in 60 sec‐
onds.
rrectness of i
l purpos
– Remove fuel delivery unit and check filter strainer for dirt
nform
ercia
– Check fuel lines for leaks and damage.

m
a
com
tio
– Ensure that all hose connections are properly connected to
n in
r
fuel delivery unit.

te o
thi
s
iva
do
If no fault is detected:
r
rp
cum
fo
en
– Check current draw of fuel pump
ng
t.
yi Co
⇒ “7.1.5 Checking current consumption”, page 51 . t. Cop py
rig
gh ht
If no fault was detected in the current draw: pyri by
Vo
o
by c lksw
cted agen
– Renew flange for fuel delivery unit Prote AG.
Note
Pressure limiting valve and fuel filter are integrated in flange of

fuel delivery unit and cannot be renewed individually.
– Repeat fuel delivery rate check at fuel delivery unit

⇒ page 48 .
If fuel delivery rate has been attained, but nevertheless you sus‐
pect a fuel supply system fault (e.g. intermittent failure of fuel
supply system):
– Check current draw of fuel pump
⇒ “7.1.5 Checking current consumption”, page 51 .
7.1.5 Checking current consumption

7. Fuel pump 51
Passat CC 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
♦ Pick-up clamp e.g. pick-up clamp - V.A.G 1526B/2-
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note

joined.
⇒ page 23 .
♦ Separate plug-in connectors

seats .

Passat CC 2009 ➤
Fuel supply Asystem,
G. Volkswpetrol
agenA engines - Edition 05.2019
n G do
wage es n
Volks ot g
– Remove cover -1- with fuel pump control unit ed - J538- -2- from
by ua
ran
fuel delivery unit. oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Check that connector -1- is fitted securely by pulling connector
without pressing catch. If connector was not inserted correctly,
l purpos
repeat functional check of fuel pump.

– Unplug connector -1-.
nf
ercia
or
m
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
connector and fuel delivery unit. Prote AG.
– Connect pick-up clamp -A- to red terminal with lettering “pick-

up clamp” for test instrument adapter/DSO (5-pin) - VAS
5565- .
– Run engine at idling speed.
– Measure current draw of fuel pump.
• Specification: max. 10 amps
Note
♦ The starting current for the fuel pump can be briefly above
specifications when starting the engine.
♦ If the fault in the fuel system is not always evident, the check
can also be carried out during a road test. A 2nd person is
required to do this, however.
If the current draw is exceeded:

– Check fuel lines for possible restrictions (kinks) or blockages.
– Remove fuel delivery unit ⇒ page 17 and check for contami‐
nation.
– Checking fuel pressure ⇒ page 37 .
– Renew fuel delivery unit ⇒ page 17 .
7. Fuel pump 53

D3E8047B900-Fuel Supply System Petrol Engines

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Service

Fuel supply system, petrol engines

Service Department. Technical Information

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Copyright © 2019 Volkswagen AG, Wolfsburg D3E8047B900

2 Fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.2 Removing and installing fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

5 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

5.2 Checking fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1.1 Safety regulations for working on fuel supply

Danger of fire caused by escaping fuel

1.2 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

2 Rep. gr.00 - Technical data

2.1 Engine number/engine data

3.1 Rules for cleanliness when working on

4 Rep. gr.00 - Technical data

20 – Fuel supply system

1.1 Assembly overview - fuel tank

♦ Plug-in connectors must engage »audibly« when joined.

tank flap unit .

❑ Clipped onto fuel tank

❑ Ensure firm seating

❑ Ensure firm seating

⇒ “1.2 Removing and in‐

⇒ “1.3 Emptying fuel

To secure the securing straps for

the fuel tank, only bolts with loose

washers must be used. This will

stop the securing straps from being

❑ When installing, fit dry in fuel tank opening.

13 - Fuel delivery unit

❑ With 6 bar pressure relief valve

1.2 Removing and installing fuel tank

6 Rep. gr.20 - Fuel supply system

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

♦ Engine and gearbox jack - V.A.G 1383 A-

– Check whether a coded radio is fitted. If so, obtain anti-theft spec

Drain fuel tank with fuel extractor - VAS 5190 A- ⇒ page 11 .

72 ; Rear seats; Removing and installing bench seat/individual

valve off upwards.

– Unbolt filler neck from body -arrows-.

– Unclip wire from filler neck -arrows-.

8 Rep. gr.20 - Fuel supply system

– Separate breather line (white) and fuel line (black) at union.

When lowering, ensure sufficient clearance to brake lines and

– Unscrew bolts of tensioning straps -arrows-.

Secure fuel tank to prevent it falling down.

– Remove tensioning straps.

Tighten securing bolts -arrows-.

– Fill fuel tank with at least 5 litres of fuel.

Risk of severe injuries and burns.

– If a new or completely empty fuel tank has been installed, fill

it immediately with at least 5 litres of fuel.

Filler neck to body 8 Nm +90°

Fitting wheels ⇒ Running gear, axles, steering; Rep. gr. 44 ; Wheels,

10 Rep. gr.20 - Fuel supply system

1.3 Emptying fuel tank

1.3.1 Emptying fuel tank when fuel pump is intact

Special tools and workshop

♦ Removal wedge - 3409-

tractor - VAS 5190 /3- to fuel supply line.