Fuel supply system, petrol engines_SEAT LEON MK3 2017

Service
Workshop Manual
León 2013 ➤
León ST 2013 ➤
Fuel supply system, petrol engines
Engine ID
CMB CHP CJZA CJZB CJSA CXS CJXA CJXE CYV
A
A
A
A
CYV CZC CZE CWV CHZ CZD CJXH CJSB CJXC
B
A
A
A
D
A
Edition 02.2017
Service Department. Technical Information
Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
20 - Fuel supply system
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.
D3E804FD5C5
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1.1
1.2
1.3
2
2.1
3
3.1
4
4.1
4.2
4.3
1
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety precautions for working on vehicles with start-stop system. . . . . . . . . . . . . . . . . . .
Safety precautions during road tests in which testing and measuring equipment is used . .
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine identification number / engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleanliness specifications for working on the auxiliary heater and fuel system . . . . . . . . . .
Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Notes on general repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Routing and attaching pipes and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
2
3
3
4
4
5
5
5
5
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
1
1.1
1.2
1.3
2
2.1
2.2
3
3.1
3.2
4
4.1
5
6
6.1
6.2
6.3
7
7.1
7.2
8
8.1
8.2
8.3
Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Fuel supply unit / fuel supply sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Assembly overview - fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Removing and installing fuel delivery unit/fuel supply sender . . . . . . . . . . . . . . . . . . . . . . 55
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Removing and installing the fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Removing and installing fuel gauge sender 2 G169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Quick-release couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Separating push-on couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Activated charcoal filter system: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Exploded view - activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Removing and installing activated charcoal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Checking the fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Accelerator control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Assembly overview - accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Removing and installing accelerator module GX2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Checking fuel system pressurisation pump G6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Removing and installing fuel pump control unit J538 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Removing and installing suction-jet pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Contents
i
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
ii Contents
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
00 –
Technical data
1
Safety instructions
(ERL003307; Edition 02.2017)
⇒ “1.1 Safety precautions when working on fuel supply system”,
page 1
⇒ “1.2 Safety precautions for working on vehicles with start-stop
system.”, page 1
⇒ “1.3 Safety precautions during road tests in which testing and
measuring equipment is used”, page 2
1.1
Safety precautions when working on fuel supply system
Risk of injury due to highly-pressurised fuel.
The fuel system is pressurised. Risk of injury caused by fuel spill‐
age
Before opening the fuel system:
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
Procedure for releasing pressure in high pressure fuel system ⇒
Rep. gr. 24 ; Injection system; Releasing pressure in high pres‐
sure fuel system .
Risk of fire due to escaping fuel
If the battery is connected, the door contact switch will activate
the fuel pump when the door is opened. Escaping fuel may ignite
and cause a fire.
– Disconnect the fuel pump from the power supply before open‐
ing the fuel system.
1.2
Safety precautions for working on vehicles with start-stop system.
Risk of injury due to unexpected engine start
In vehicles with activated Start/Stop system, the engine may start
up unexpectedly. The status of the Start/Stop system is indicated
by a message in the dash panel insert.
– Deactivate Start/Stop system by switching off the ignition.
1. Safety instructions
1
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
1.3
Safety precautions during road tests in which testing and measuring equip‐
ment is used
Risk of injury due to unsecured test and measuring equipment
If a front passenger airbag is triggered during an accident, unse‐
cured test and measuring equipment can become dangerous
projectiles.
– Secure test and measuring equipment with seat belts on the
rear seat.
or
– Have a second person operate test and measuring equipment
on the rear seat.
2 Rep. gr.00 - Technical data
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
2
Identification
⇒ “2.1 Engine identification number / engine data”, page 3
2.1
Code
Engine identification number / engine data
CHZD
CJZA
CJZB
CYVA
CYVB
CHPA
CZDA
CMBA
Emission
EU6
EU5
EU5
EU6
EU6
EU5
EU5
EU5
standards
Ca‐
ltr.
1.0
1.2
1.2
1.2
1.2
1.4
1.4
1.4
pacity
En‐
kW
85
77
63
63
81
103
110
90
gine
output
RON
95 unlea‐ 95 unlea‐ 95 unlea‐ 95 unlea‐ 95 unlea‐ 95 unlea‐ 95 unlea‐ 95 unlea‐
ded
ded
ded
ded
ded
ded
ded1)
ded1)
1) In exceptional cases, 91 RON as a minimum, but with a loss of
power
Cod
e
CX CZ CZ CW CJ CJ CJ CJ CJ CJ
SA CA EA VA SA SB XA XC XE XH
Emis EU EU EU EU EU EU EU EU EU EU
sion
5
6
6
3, 66
6
6
6
5
stan
EU EU
dard
4,
2
s
EU DD
5
K
C lt 1.4 1.4 1.4 1.6 1.8 1.8 2.0 2.0 2.0 2.0
ap r.
ac
ity
En k 90 92 110 81 132 132 206 221 195 213
gi W
ne
ou
tp
ut
RON 95 95 95 95 95 95 95 95 95 95
un‐ un‐ un‐ un‐ un‐ un‐ un‐ un‐ un‐ un‐
lea‐ lea‐ lea‐ lea‐ lea‐ lea‐ lea‐ lea‐ lea‐ lea‐
ded ded ded ded ded ded ded ded ded ded
1)
1)
2. Identification
3
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
3
General notes
⇒ “3.1 Cleanliness specifications for working on the auxiliary
heater and fuel system”, page 4
3.1
Cleanliness specifications for working
on the auxiliary heater and fuel system
When working on the fuel supply and injection system, pay careful
attention to the following “five rules”:
♦ Thoroughly clean connections and surrounding area before
releasing them.
♦ Place removed parts on a clean surface and cover them up.
Use only lint-free cloths.
♦ If repairs cannot be carried out immediately, carefully cover or
seal open components.
♦ Only install clean components: the parts must be removed
from the packaging immediately before installation. Do not use
parts that have been stored loose (e.g. in toolboxes etc.).
♦ When the system is open: Do not work with compressed air.
♦ Do not move vehicle.
♦ Immediately seal open lines and unions with clean plugs, for
example from engine bung set - VAS 6122- .
♦ Protect unplugged electrical connectors against dirt and mois‐
ture and make sure connections are dry when attaching.
4 Rep. gr.00 - Technical data
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
4
Repair notes
⇒ “4.1 Notes on general repairs”, page 5
⇒ “4.2 Contact corrosion”, page 5
⇒ “4.3 Routing and attaching pipes and wiring”, page 5
4.1
Notes on general repairs
•
Battery in support mode ⇒ Rep. gr. 27 ; Battery .
•
Fuel pump fuse OK ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.
•
Fuel pump control unit - J538- OK; checking in Guided Fault
Finding ⇒ Vehicle diagnostic tester.
•
Fuel tank to at least 1/4 full.
•
Fuel filter OK.
•
Fuel lines OK (not obstructed or crushed).
•
Ignition switched off.
4.2
Contact corrosion
Contact corrosion can occur if unsuitable connecting elements
(bolts, nuts, washers...) are used.
For this reason, joint elements are mounted only with surfaces
treated with a special cover.
In addition, all rubber and plastic parts and all adhesives are made
of non-conductive materials.
Always install new parts if you are not sure whether used parts
can be re-fitted ⇒ Electronic parts catalogue .
Take into account:
♦ We recommend using only genuine replacement parts; these
have been tested and are compatible with aluminium.
♦ We recommend the use of seat accessories.
♦ Damage caused by contact corrosion are excluded from the
guarantee.
4.3
Routing and attaching pipes and wiring
Risk of damage to lines
Lines may become damaged by moving or hot components.
– Route lines in their original positions.
– Ensure that there is sufficient clearance to all moving or hot
components.
♦ Mark lines prior to removal to prevent them from being inter‐
changed and to ensure that they are fitted in their original
positions. Make drawings or take photos if needed.
4. Repair notes
5
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Fuel supply system, petrol engines - Edition 02.2017
20 –
Fuel supply system
1
Fuel tank
⇒ “1.1 Assembly overview - fuel tank”, page 6
⇒ “1.2 Removing and installing fuel tank”, page 11
⇒ “1.3 Emptying fuel tank”, page 34
1.1
Assembly overview - fuel tank
⇒ “1.1.1 Assembly overview - fuel tank, vehicles with multi-link
rear suspension”, page 6
⇒ “1.1.2 Assembly overview - fuel tank, vehicles with front drive
and trailing arm rear suspension”, page 8
⇒ “1.1.3 Exploded view - fuel tank (vehicles with four-wheel
drive)”, page 10
1.1.1
Assembly overview - fuel tank, vehicles with multi-link rear suspension
1 - Fuel supply line
❑ To engine
❑ Partly covered by the
fuel tank
❑ Do not kink.
❑ To remove press re‐
lease tab on connection
element
❑ Connections for fuel
lines must engage audi‐
bly when joined.
❑ Ensure push-fit cou‐
plings are secured prop‐
erly by pulling.
❑ Opening the quick-re‐
lease couplings
⇒ page 68
2 - Bleeder hose
❑ To activated charcoal fil‐
ter solenoid valve 1 N80❑ Clipped onto fuel tank.
❑ Do not kink.
❑ To remove press re‐
lease tab on connection
element
❑ Connections for fuel
lines must engage audi‐
bly when joined.
❑ Ensure push-fit cou‐
plings are secured prop‐
erly by pulling.
❑ Opening the quick-re‐
lease couplings
⇒ page 68
3 - Support bracket
❑ For fuel pump control unit - J538-
6 Rep. gr.20 - Fuel supply system
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
4 - Bolt.
❑ Must be renewed if removed
❑ 20 Nm + 90°
5 - Bolt.
❑ Must be renewed if removed
❑ 8 Nm + 90°
6 - Sealing cap
❑ Screw down until it clicks audibly
❑ Fitted on tank flap unit with a securing device
7 - Bolt.
❑ Must be renewed if removed
❑ To secure fuel filler neck
❑ For diverting electrostatic charge
❑ 8 Nm + 90°
8 - Earth connection
❑ For fuel filler neck
❑ For diverting electrostatic charge
9 - Bleeder hose
❑ To activated charcoal filter
❑ Clipped onto fuel tank.
❑ Do not kink.
❑ To remove press release tab on connection element
❑ Connections for fuel lines must engage audibly when joined.
❑ Ensure push-fit couplings are secured properly by pulling.
❑ Opening the quick-release couplings ⇒ page 68
10 - Bleeder hose
❑ To activated charcoal filter
❑ Clipped onto fuel tank.
❑ Do not kink.
❑ To remove press release tab on connection element
❑ Connections for fuel lines must engage audibly when joined.
❑ Ensure push-fit couplings are secured properly by pulling.
❑ Opening the quick-release couplings ⇒ page 68
11 - Fuel tank
❑ Removing and fitting ⇒ page 11
12 - Bolt.
❑ Must be renewed if removed
❑ 20 Nm + 90°
13 - Nut
❑ For heat shield
❑ 2 Nm
14 - Heat shield
❑ For fuel tank
15 - Securing strap
16 - Bolts
❑ Must be renewed if removed
❑ 20 Nm + 90°
1. Fuel tank
7
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
1.1.2
Assembly overview - fuel tank, vehicles with front drive and trailing arm rear
suspension
1 - Sealing cap
❑ Screw down until it
clicks audibly
❑ Fitted on tank flap unit
with a securing device
2 - Earth connection
❑ For fuel filler neck
❑ For diverting electro‐
static charge
3 - Bolt.
❑ Must be renewed if re‐
moved
❑ 8 Nm + 90°
4 - Locking ring
❑ 110 Nm ± 5 Nm
5 - Oil seal
❑ seal
❑ Mount dry
6 - Fuel delivery unit
❑ Assembly overview
⇒ page 52
❑ Removing and fitting
⇒ page 55
❑ With fuel level indicator
sensor - G❑ Removing and installing
the fuel gauge sender G- ⇒ page 64
❑ With the fuel pump
(pressurisation pump) G6❑ Check the fuel pump
(pressurisation pump) - G6- ⇒ page 83
❑ Connections on fuel delivery unit
7 - Fuel tank
❑ Removing and fitting ⇒ page 17
8 - Heat shield
❑ For fuel tank
9 - Locking plate
❑ 4 pieces
❑ For heat shield
10 - Securing strap
❑ Ensure proper seating
❑ Mark the direction before removal
11 - Bolt.
❑ Must be renewed if removed
❑ 20 Nm + 90°
8 Rep. gr.20 - Fuel supply system
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
12 - Support bracket
❑ For fuel pump control unit - J538❑ Removing and installing fuel pump control unit - J538- ⇒ page 126 .
13 - Fuel supply line
❑ Partly covered by the fuel tank
❑ Do not kink.
❑ To remove press release tab on connection element
❑ Connections for fuel lines must engage audibly when joined.
❑ Ensure push-fit couplings are secured properly by pulling.
❑ Opening the quick-release couplings ⇒ page 68
14 - Bleeder hose
❑ To activated charcoal filter
❑ From activated charcoal filter solenoid valve 1 - N80❑ Do not kink.
❑ To remove press release tab on connection element
❑ Connections for fuel lines must engage audibly when joined.
❑ Ensure push-fit couplings are secured properly by pulling.
❑ Opening the quick-release couplings ⇒ page 68
❑ Checking breather ⇒ page 75
❑ Connection schema ⇒ page 74
15 - Bleeder hose
❑ To activated charcoal filter
❑ Clipped onto fuel tank.
❑ Do not kink.
❑ To remove press release tab on connection element
❑ Connections for fuel lines must engage audibly when joined.
❑ Ensure push-fit couplings are secured properly by pulling.
❑ Opening the quick-release couplings ⇒ page 68
❑ Checking breather ⇒ page 75
❑ Connection schema ⇒ page 74
1. Fuel tank
9
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Fuel supply system, petrol engines - Edition 02.2017
1.1.3
Exploded view - fuel tank (vehicles with four-wheel drive)
1 - Breather line
❑ To activated charcoal fil‐
ter
❑ Do not kink.
❑ Partly covered by the
fuel tank
❑ To remove press re‐
lease tab on connection
element
❑ Connect so it engages
audibly
❑ Press in again and then
pull to check that plug-in
connector is correctly
engaged
2 - Breather line
❑ To activated charcoal fil‐
ter
❑ Do not kink.
❑ To remove press re‐
lease tab on connection
element
❑ Connect so it engages
audibly
❑ Press in again and then
pull to check that plug-in
connector is correctly
engaged
3 - Bolts
❑ 20 Nm
4 - Fuel tank
❑ Removing and fitting
⇒ page 11
5 - Securing strap (left-side)
6 - Bolt.
❑ 20 Nm
7 - Nut
❑ For heat shield
❑ 2 Nm
8 - Heat shield
❑ For fuel tank
9 - Securing strap (right-side)
10 - Bolt.
❑ 20 Nm
11 - Fuel line
❑ To engine
❑ Do not kink.
❑ Partly covered by the fuel tank
❑ To remove press release tab on connection element
❑ Connect so it engages audibly
10 Rep. gr.20 - Fuel supply system
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
❑ Press in again and then pull to check that plug-in connector is correctly engaged
12 - Fuel pump control unit - J538❑ Removing and fitting ⇒ page 126
13 - Bolt.
❑ 8 Nm
14 - Sealing plug
❑ Screw down until it clicks audibly
❑ Fastened with a safety line on the tank flap unit
15 - Bolt.
❑ To secure fuel filler neck
❑ For diverting electrostatic charge
❑ 8 Nm
1.2
Removing and installing fuel tank
⇒ “1.2.1 Removing and installing fuel tank, vehicles with multi-link
suspension”, page 11
⇒ “1.2.2 Removing and installing fuel tank, vehicles with torsion
beam axle”, page 17
⇒ “1.2.3 Removing and installing fuel tank, vehicles with torsion
beam axle, engine code CWVA”, page 23
⇒ “1.2.4 Removing and installing fuel tank - vehicles with fourwheel drive”, page 28
1.2.1
Removing and installing fuel tank, vehi‐
cles with multi-link suspension
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-
♦ Wedge - 3409-
1. Fuel tank
11
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
♦ Engine/gearbox jack - VAS 6931-
♦ Torque wrench - V.A.G 1332-
Removal:
– Drain fuel tank ⇒ page 34 .
– Move front seats as far forwards as possible.
– Switch off ignition.
– Remove rear seat bench ⇒ General body repairs, interior;
Rep. gr. 72 ; Rear seats; Removing and installing seat bench/
individual seats .
– Unclip cover -1- of cover flange from the retaining tabs using
the lever - 3409- -arrows-.
12 Rep. gr.20 - Fuel supply system
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
– Clip sealing grommet -1- downwards from cover -2-.
– Guide cover -2- along wiring harness -3- backwards.
– Release and pull off connector -1- on sealing flange.
– Push tab -2- up in -direction of arrow A-.
– To do this, reach in with your finger between the floor plate
and fuel tank.
– At the same time, carefully pull fuel pump control unit - J538-1- out of mounting -in direction of arrow B- by grasping hold
of wiring harness -3-.
– Guide fuel pump control unit - J538- out towards interior be‐
tween fuel tank and floor panel.
– Open tank flap unit -2-.
– Clean area around fuel filler neck.
– Unscrew cap -1- for fuel filler neck.
Note
Seal off opening of fuel filler neck with a clean plug to prevent dirt
from entering.
– Remove tank flap unit -2- ⇒ General body repairs, exterior;
Rep. gr. 55 ; Tank flap unit; remove and install tank flap unit .
– Remove rear right-hand wheel ⇒ Running gear, axles, steer‐
ing; Rep. gr. 44 ; Wheels, tyres .
– Remove rear right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liner; Assembly
overview - rear wheel housing liner .
1. Fuel tank
13
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
– Remove bolts -1- and -2- for fuel filler neck.
– Pull breather lines -1- and -2- off activated charcoal filter.
Opening the quick-release coupling ⇒ page 68 .
– Unclip breather pipes from bracket -arrow-.
– Disconnect breather lines -1- and -2- from retainer -arrows-.
– Remove rear silencer ⇒ Rep. gr. 26 ; Exhaust pipe / Silencer;
Assembly overview - silencer .
– Disconnect fuel line -1- on underbody. Opening the quick-re‐
lease coupling ⇒ page 68 .
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
– Disconnect breather lines -2-. Opening the quick-release cou‐
plings ⇒ page 68
14 Rep. gr.20 - Fuel supply system
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
– Screw out bolt -4-.
– Remove bracket for exhaust gas system.
– Unscrew bolt -2- and remove securing strap.
– Place engine and gearbox jack - VAS 6931- underneath for
support and prop up fuel tank -1-, as shown in illustration.
1. Fuel tank
15
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
– Unscrew bolts -1- and -3-.
Note
♦ For illustration purposes the fuel tank is shown without the en‐
gine and gearbox jack - VAS 6931- .
♦ The aid of a 2nd mechanic is required to remove the fuel tank.
– Lower fuel tank with engine and gearbox jack - VAS 6931- .
– Lower fuel tank by turning it sideways.
– Observe lines to activated charcoal filter (unclip them, if nec‐
essary).
– Guide filler neck out between rear axle and body.
Installation
Installation is in the reverse sequence of removal. The following
must be taken into account:
– Insert filler neck between rear axle and body.
Note
Opening the quick-release coupling ⇒ page 68 .
– Make sure that the filler neck of the fuel tank is correctly in‐
serted into the opening in the body.
– The breather and fuel lines are to be installed without any
kinks.
– After installing fuel tank, check that the supply, return and
breather lines are still clipped onto the fuel tank.
– Position the fuel tank together with retaining strap on under‐
body, using the engine and gearbox jack - VAS 6931- .
– Check correct seat of the exhaust system bracket ⇒ Rep. gr.
26 ; Exhaust pipes / Silencers .
– Note position of securing strap.
– Ensure that line connections are tight.
– Ensure connections are secured properly by pulling.
16 Rep. gr.20 - Fuel supply system
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
– Check earth wire for traces of oxidation at connectors; remove
any oxidation if necessary.
– Check installation position of earth connection.
•
Ensure connector -2- is seated properly on metal ring-3-.
•
The contact tab -1- must be hooked on the fuel tank -4- and
secured using a distance bushing -5-.
– Check connection of metal ring on fuel filler neck by measuring
between ring and a bare metal part of the body.
•
Specification: approx. 0 Ohm
•
If the specification is not attained, there is a risk of explosion
due to electrostatic discharge.
– Fill fuel tank with at least 5 litres of fuel.
WARNING
Risk of explosion of fuel tank caused by fuel pump activation.
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.
Specified torques
♦ ⇒ “1.1.1 Assembly overview - fuel tank, vehicles with multi-link
rear suspension”, page 6
♦ ⇒ Rep. gr. 72 ; Rear seats; assembly overview - seat bench /
individual seats (rear) .
♦ ⇒ Rep. gr. 26 ; Exhaust pipes/silencer .
♦ ⇒ Rep. gr. 55 ; Tank flap unit; assembly overview - tank flap
unit.
♦ ⇒ Rep. gr. 66 ; Wheel housing liner; assembly overview - rear
wheel housing liner .
1.2.2
Removing and installing fuel tank, vehi‐
cles with torsion beam axle
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-
1. Fuel tank
17
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
♦ Wedge - 3409-
♦ Torque wrench - V.A.G 1332-
♦ Engine/gearbox jack - VAS 6931-
– Fuel tank: draining ⇒ page 34 .
– Move front seats as far forwards as possible.
– Switch off ignition.
– Remove rear bench seat ⇒ General body repairs - interior;
Rep. gr. 72 ; Rear seats; Assembly overview - Rear bench
seat / Single seats .
– Unclip cover -1- of cover flange from the retaining tabs using
the lever - 3409- -arrows-.
18 Rep. gr.20 - Fuel supply system
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
– Clip sealing grommet -1- downwards from cover -2-.
– Guide cover -2- along wiring harness -3- backwards.
– Release and pull off connector -1- on sealing flange.
– Push tab -2- up in -direction of arrow A-.
– To do this, reach in with your finger between the floor plate
and fuel tank.
– At the same time, carefully pull fuel pump control unit - J538-1- out of mounting in direction of arrow -B- by grasping hold
of wiring harness -3-.
– Guide fuel pump control unit - J538- out towards interior be‐
tween fuel tank and floor panel.
– Open tank flap unit -2-.
– Clean area around fuel filler neck.
– Unscrew cap -1- for fuel filler neck.
Note
Seal off opening of fuel filler neck with a clean plug to prevent dirt
from entering.
– Remove tank flap unit -2- ⇒ General body repairs, exterior;
Rep. gr. 55 ; Tank flap unit; remove and install tank flap unit .
– Remove rear wheel (right-side) ⇒ Rep. gr. 44 ; Wheels and
tyres .
– Remove the rear right-hand side wheel housing liner ⇒ Body‐
work, exterior fitting work; Rep. gr. 66 ; Rear wheel housing
liner, Wheel housing liner removing and installing .
1. Fuel tank
19
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
– Pull breather lines -1- and -2- off activated charcoal filter.
Opening the quick-release coupling ⇒ page 68 .
– Unclip breather lines -1- from retainer -arrow-.
– Remove bolts -1- and -2- for fuel filler neck.
– Remove rear silencer ⇒ Rep. gr. 26 ; Exhaust pipe / Silencer;
Assembly overview - silencer .
– Remove rear right suspension spring ⇒ Running gear, axles,
steering; Rep. gr. 42 ; Telescopic arm / Shock absorbers,
spring; Removing and installing spring .
– Remove rear right shock absorber ⇒ Running gear, axles,
steering; Rep. gr. 42 ; Telescopic arm / Shock absorbers,
spring; Removing and installing shock absorber .
– Disconnect fuel line -1- on underbody. Opening the quick-re‐
lease coupling ⇒ page 68 .
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
– Disconnect breather pipe -2-. Opening the quick-release cou‐
pling ⇒ page 68 .
20 Rep. gr.20 - Fuel supply system
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
– Screw out bolt -5-.
– Remove bracket for exhaust gas system -arrow-.
– Unscrew bolt -3- and remove the retaining strap -7-.
– Place engine and gearbox jack - VAS 6931- underneath for
support and prop up fuel tank -1-, as shown in illustration.
1. Fuel tank
21
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
– Unscrew screws -2-, -4- and -6- .
Note
♦ For a better understanding, the fuel tank is shown without the
rear axle.
♦ The aid of a 2nd mechanic is required to remove the fuel tank.
Note
When removing the »fuel tank«, proceed carefully in order not to
damage it.
– Lower fuel tank by turning it sideways.
– Guide filler neck out between rear axle and body.
Installation
Installation is in the reverse sequence of removal. The following
must be taken into account:
Note
Opening the quick-release coupling ⇒ page 68 .
– The breather and fuel lines are to be installed without any
kinks.
– Make sure that the filler neck of the fuel tank is correctly in‐
serted into the opening in the body.
– Position the fuel tank together with retaining strap on under‐
body, using the engine and gearbox jack - VAS 6931- .
– Note position of securing strap.
– After installing fuel tank, check that the supply, return and
breather lines are still clipped onto the fuel tank.
– Check correct seat of the exhaust system bracket ⇒ Rep. gr.
26 ; Exhaust pipes / Silencer; Exhaust system: fit into position
without tension .
– Ensure that line connections are tight.
– Ensure connections are secured properly by pulling.
22 Rep. gr.20 - Fuel supply system
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
– Check earth wire for traces of oxidation at connectors; remove
any oxidation if necessary.
– Check installation position of earth connection.
•
Ensure connector -2- is seated properly on metal ring-3-.
•
The contact tab -1- must be hooked on the fuel tank -4- and
secured using a distance bushing -5-.
– Check connection of metal ring on fuel filler neck by measuring
between ring and a bare metal part of the body.
•
Specification: approx. 0 Ohm
•
If the specification is not attained, there is a risk of explosion
due to electrostatic discharge.
– Fill fuel tank with at least 5 litres of fuel.
WARNING
Risk of explosion of fuel tank caused by fuel pump activation.
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.
Specified torques
♦ ⇒ “1.1.2 Assembly overview - fuel tank, vehicles with front
drive and trailing arm rear suspension”, page 8
♦ ⇒ General body repairs, interior; Rep. gr. 72 ; Rear seats;
rear seat bench / remove and install individual seats (rear) .
♦ ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Assembly overview
– silencers
♦ ⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit;
Removing and installing tank flap unit .
♦ ⇒ Running gear, axles, steering; Rep. gr. 42 ; Rear axle;
Removing and installing rear axle .
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody
cover .
1.2.3
Removing and installing fuel tank, vehi‐
cles with torsion beam axle, engine code
CWVA
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-
1. Fuel tank
23
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
♦ Wedge - 3409-
♦ Torque wrench - V.A.G 1332-
♦ Engine/gearbox jack - VAS 6931-
– Fuel tank: draining ⇒ page 34 .
– Move front seats as far forwards as possible.
– Switch off ignition.
– Remove rear bench seat ⇒ General body repairs - interior;
Rep. gr. 72 ; Rear seats; Assembly overview - Rear bench
seat / Single seats .
– Unclip cover -1- of cover flange from the retaining tabs using
the lever - 3409- -arrows-.
24 Rep. gr.20 - Fuel supply system
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
– Clip sealing grommet -1- downwards from cover -2-.
– Guide cover -2- along wiring harness -3- backwards.
– Release and pull off connector -arrow- on sealing flange.
– Open tank flap unit -2-.
– Clean area around fuel filler neck.
– Unscrew cap -1- for fuel filler neck.
Note
Seal off opening of fuel filler neck with a clean plug to prevent dirt
from entering.
– Remove tank flap unit -2- ⇒ General body repairs, exterior;
Rep. gr. 55 ; Tank flap unit; remove and install tank flap unit .
– Remove rear wheel (right-side) ⇒ Rep. gr. 44 ; Wheels and
tyres .
– Remove the rear right-hand side wheel housing liner ⇒ Body‐
work, exterior fitting work; Rep. gr. 66 ; Rear wheel housing
liner, Wheel housing liner removing and installing .
– Pull breather lines -1- and -2- off activated charcoal filter.
Opening the quick-release coupling ⇒ page 68 .
1. Fuel tank
25
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
– Unclip breather lines -1- from retainer -arrow-.
– Remove bolts -1- and -2- for fuel filler neck.
– Remove rear silencer ⇒ Rep. gr. 26 ; Exhaust pipe / Silencer;
Assembly overview - silencer .
– Remove rear right suspension spring ⇒ Running gear, axles,
steering; Rep. gr. 42 ; Telescopic arm / Shock absorbers,
spring; Removing and installing spring .
– Remove rear right shock absorber ⇒ Running gear, axles,
steering; Rep. gr. 42 ; Telescopic arm / Shock absorbers,
spring; Removing and installing shock absorber .
– Disconnect fuel line -1- on underbody. Opening the quick-re‐
lease coupling ⇒ page 68 .
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
– Disconnect breather pipe -2-. Opening the quick-release cou‐
pling ⇒ page 68 .
– Screw out bolt -5-.
– Remove bracket for exhaust gas system -arrow-.
– Unscrew bolt -3- and remove the retaining strap -7-.
26 Rep. gr.20 - Fuel supply system
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
– Place engine and gearbox jack - VAS 6931- underneath for
support and prop up fuel tank -1-, as shown in illustration.
– Unscrew screws -2-, -4- and -6- .
Note
♦ For a better understanding, the fuel tank is shown without the
rear axle.
♦ The aid of a 2nd mechanic is required to remove the fuel tank.
Note
When removing the »fuel tank«, proceed carefully in order not to
damage it.
– Lower fuel tank by turning it sideways.
– Guide filler neck out between rear axle and body.
Installation
Installation is in the reverse sequence of removal. The following
must be taken into account:
Note
Opening the quick-release coupling ⇒ page 68 .
– The breather and fuel lines are to be installed without any
kinks.
– Make sure that the filler neck of the fuel tank is correctly in‐
serted into the opening in the body.
– Position the fuel tank together with retaining strap on under‐
body, using the engine and gearbox jack - VAS 6931- .
– Note position of securing strap.
– After installing fuel tank, check that the supply, return and
breather lines are still clipped onto the fuel tank.
– Check correct seat of the exhaust system bracket ⇒ Rep. gr.
26 ; Exhaust pipes / Silencer; Exhaust system: fit into position
without tension .
– Ensure that line connections are tight.
– Ensure connections are secured properly by pulling.
1. Fuel tank
27
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
– Check earth wire for traces of oxidation at connectors; remove
any oxidation if necessary.
– Check installation position of earth connection.
•
Ensure connector -2- is seated properly on metal ring-3-.
•
The contact tab -1- must be hooked on the fuel tank -4- and
secured using a distance bushing -5-.
– Check connection of metal ring on fuel filler neck by measuring
between ring and a bare metal part of the body.
•
Specification: approx. 0 Ohm
•
If the specification is not attained, there is a risk of explosion
due to electrostatic discharge.
– Fill fuel tank with at least 5 litres of fuel.
WARNING
Risk of explosion of fuel tank caused by fuel pump activation.
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.
Specified torques
♦ ⇒ “1.1.2 Assembly overview - fuel tank, vehicles with front
drive and trailing arm rear suspension”, page 8
♦ ⇒ General body repairs, interior; Rep. gr. 72 ; Rear seats;
rear seat bench / remove and install individual seats (rear) .
♦ ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Assembly overview
– silencers
♦ ⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit;
Removing and installing tank flap unit .
♦ ⇒ Running gear, axles, steering; Rep. gr. 42 ; Rear axle;
Removing and installing rear axle .
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liner; Assembly overview- rear wheel housing liner .
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody
cover .
1.2.4
Removing and installing fuel tank - ve‐
hicles with four-wheel drive
Special tools and workshop equipment required
♦ Wedge - 3409-
28 Rep. gr.20 - Fuel supply system
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
♦ Torque wrench - V.A.G 1332-
♦ Engine/gearbox jack - VAS 6931-
– Fuel tank: draining ⇒ page 34 .
– Move front seats as far forwards as possible.
– Switch off ignition.
– Remove rear bench seat ⇒ General body repairs - interior;
Rep. gr. 72 ; Rear seats; Assembly overview - Rear bench
seat / Single seats .
– Unclip cover -1- on left and right at retaining tabs in direction
of -arrows- using removal wedge - 3409- .
– Release and pull off connector -arrow-.
– Lay cover -1- with wiring harness to one side.
1. Fuel tank
29
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
– Press up tab -2- in -direction of arrow A-; to do so, reach be‐
tween floor panel and fuel tank with your finger.
– At the same time, carefully pull fuel pump control unit - J538-1- out of mounting -in direction of arrow B- by grasping hold
of wiring harness -3-.
– Guide fuel pump control unit - J538- out towards interior be‐
tween fuel tank and floor panel.
– Unplug electrical connectors -1- and -2-.
– Open tank flap unit -2-.
– Clean area around fuel filler neck.
– Unscrew cap -1- for fuel filler neck.
Note
Seal off opening of fuel filler neck with a clean plug to prevent dirt
from entering.
– Remove tank flap unit -2- ⇒ General body repairs, exterior;
Rep. gr. 55 ; Tank flap unit; remove and install tank flap unit .
– Remove rear wheel (right-side) ⇒ Rep. gr. 44 ; Wheels and
tyres .
– Remove the rear right-hand side wheel housing liner ⇒ Body‐
work, exterior fitting work; Rep. gr. 66 ; Rear wheel housing
liner, Wheel housing liner removing and installing .
30 Rep. gr.20 - Fuel supply system
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
– Unscrew bolts -1 and 2- for fuel filler neck.
– Pull breather lines -1 and 2- off activated charcoal filter.
– To do so, press release tab and pull connection piece off con‐
nection.
– Unclip breather lines from retainer -arrows-.
– Unclip breather lines -1 and 2- from retainer -arrow- on sub‐
frame.
– Remove propshaft ⇒ Propshaft and rear final drive; Rep. gr.
39 ; Propshaft; Removing and installing propshaft .
– Unplug electrical connector -1- for Haldex coupling.
– Unclip wiring harness from fuel tank.
1. Fuel tank
31
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
– Unclip wiring harness -1- on the trailing arm -2- -arrows-.
– Unscrew bolts -3-, and swing trailing arm -2- downwards.
– Remove rear right brake caliper ⇒ Brake system; Rep. gr.
46 ; Rear brake; Removing and installing brake caliper .
– Do not disconnect brake line when doing this.
– Secure brake caliper on body.
– Disconnect lines -1 and 2- at right side of underbody.
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
– Place engine and gearbox jack - VAS 6931- -2- underneath,
and support fuel tank -1- as shown in illustration.
32 Rep. gr.20 - Fuel supply system
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
– In addition, a second mechanic will be required to support the
fuel tank at the rear by hand.
– Remove bolts -1 … 5-.
Note
♦ For illustration purposes the fuel tank is shown without the en‐
gine and gearbox jack - VAS 6931- .
♦ The aid of a 2nd mechanic is required to remove the fuel tank.
– The second mechanic must support the fuel tank at the rear
by hand.
– Lower fuel tank with engine and gearbox jack - VAS 6931- .
– Lower fuel tank by turning it sideways.
– Guide filler neck out between rear axle and body.
– The second mechanic must take out the fuel filler neck at the
trailing arm by hand.
Installation
Installation is carried out in the reverse order; note the following:
– The breather and fuel lines are to be installed without any
kinks.
– Make sure that the filler neck of the fuel tank is correctly in‐
serted into the opening in the body.
– Position the fuel tank together with retaining strap on under‐
body, using the engine and gearbox jack - VAS 6931- .
– Note position of securing strap.
– After installing fuel tank, check that the supply, return and
breather lines are still clipped onto the fuel tank.
– Check the proper seat of the bracket for the exhaust system⇒
Rep. gr. 26 ; Exhaust pipes/silencers; Assembly overview Silencers .
– Ensure that line connections are tight.
– Ensure connections are secured properly by pulling.
1. Fuel tank
33
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
– Check earth wire for traces of oxidation at connectors; remove
any oxidation if necessary.
– Check installation position of earth connection.
•
Ensure connector -2- is seated properly on metal ring-3-.
•
The contact tab -1- must be hooked on the fuel tank -4- and
secured using a distance bushing -5-.
– Check connection of metal ring on fuel filler neck by measuring
between ring and a bare metal part of the body.
•
Specification: approx. 0 Ohm
•
If the specification is not attained, there is a risk of explosion
due to electrostatic discharge.
– Fill fuel tank with at least 5 litres of fuel.
WARNING
Risk of explosion of fuel tank caused by fuel pump activation.
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.
Specified torques
♦ ⇒ “1.1.2 Assembly overview - fuel tank, vehicles with front
drive and trailing arm rear suspension”, page 8
♦ ⇒ Propshaft and rear final drive; Rep. gr. 39 ; Propshaft; As‐
sembly overview - propshaft
♦ ⇒ General body repairs, interior; Rep. gr. 72 ; Rear seats;
rear seat bench / remove and install individual seats (rear) .
♦ ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Assembly overview
– silencers
♦ ⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit;
Removing and installing tank flap unit .
♦ ⇒ Running gear, axles, steering; Rep. gr. 42 ; Rear axle;
Removing and installing rear axle .
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liner; Assembly overview- rear wheel housing liner .
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody
cover .
1.3
Emptying fuel tank
⇒ “1.3.1 Emptying fuel tank when fuel pump is intact”,
page 34
⇒ “1.3.2 Emptying fuel tank with fuel pump intact, engine code
CWVA”, page 38
⇒ “1.3.3 Emptying fuel tank if it is more than 3/4 full”, page 41
⇒ “1.3.4 Emptying fuel tank if it is less than 3/4 full”, page 42
⇒ “1.3.5 Emptying fuel tank with fuel tank more than 3/4 full, en‐
gine code CWVA”, page 45
⇒ “1.3.6 Emptying fuel tank with fuel tank less than 3/4 full, vehi‐
cles with all-wheel drive”, page 48
1.3.1
Emptying fuel tank when fuel pump is intact
34 Rep. gr.20 - Fuel supply system
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
Special tools and workshop
equipment required
♦ Wedge - 3409♦ Remote control - V.A.G
1348/3A♦ Test instrument adapter/
DSO (5-pin) - VAS 5565♦ Fuel drainage equipment VAS 5190 A♦ Adapter for fuel extraction VAS 5190 /.1–3-
Note
To extract E 85 fuel, use only fuel extractor - VAS 5190 A- !
♦ Auxiliary measuring set - V.A.G 1594C-
1. Fuel tank
35
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
Note
If the fuel extraction unit - VAS 5190 A- is still fitted with the ex‐
traction hose with a solid tip, the extraction hose must be replaced
with the version with a screwed tip.
Note
Opening the quick-release coupling ⇒ page 68 .
– Observe safety instructions ⇒ page 1 .
– Observe rules for cleanliness ⇒ page 4 .
– Pull off fuel supply line -1-. Opening the quick-release coupling
⇒ page 68 .
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
– Collect escaping fuel with a cleaning cloth.
– Connect the fuel drainage equipment - VAS 5190 A- to the fuel
supply line using the adapter - VAS 5190 /3- .
– Secure earth wire of fuel extractor to a bare metal part of the
body.
– Remove rear seat bench ⇒ General body repairs, interior;
Rep. gr. 72 ; Rear seats; Removing and installing seat bench/
individual seats .
36 Rep. gr.20 - Fuel supply system
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
– Unclip cover -1- of cover flange from the retaining tabs using
the lever - 3409- -arrows-.
– Clip sealing grommet -1- downwards from cover -2-.
– Guide cover -2- along wiring harness -3- backwards.
– Release and pull off connector -1- on sealing flange.
– Connect test instrument adapter/DSO (5-pin) - VAS 5565- to
fuel delivery unit -1-.
– Connect remote control - V.A.G 1348/3A- to adapter - VAS
5565- and to battery positive terminal in engine compartment.
– Connect connection -5- (yellow) of test instrument adapter/
DSO (5-pin) - VAS 5565- to battery negative terminal using
suitable workshop equipment -3-.
– Also use auxiliary measuring set - V.A.G 1594C- for this pur‐
pose.
Note
The following operation is to make the fuel pump run when the
engine is stopped.
1. Fuel tank
37
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
– Open tank flap unit -2-.
– Clean area around fuel filler neck.
– Unscrew cap -1- for fuel filler neck.
– Operate remote control - V.A.G 1348/3A- and shut-off tap on
fuel extractor - VAS 5190 A- until fuel tank is empty.
NOTICE
Risk of irreparable damage to fuel pump if allowed to run dry.
– Never allow fuel pump to run »dry«.
1.3.2
Emptying fuel tank with fuel pump intact, engine code CWVA
Special tools and workshop
equipment required
♦ Wedge - 3409♦ Remote control - V.A.G
1348/3A♦ Test instrument adapter/
DSO (5-pin) - VAS 5565♦ Fuel drainage equipment VAS 5190 A♦ Adapter for fuel extraction VAS 5190 /.1–3-
38 Rep. gr.20 - Fuel supply system
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
♦ Auxiliary measuring set - V.A.G 1594C-
Note
If the fuel extraction unit - VAS 5190 A- is still fitted with the ex‐
traction hose with a solid tip, the extraction hose must be replaced
with the version with a screwed tip.
– Observe safety instructions ⇒ page 1 .
– Observe rules for cleanliness ⇒ page 4 .
– Pull off fuel supply line -1-. Opening the quick-release coupling
⇒ page 68 .
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
– Collect escaping fuel with a cleaning cloth.
– Connect fuel extractor - VAS 5190 A- with adapter for fuel ex‐
tractor - VAS 5190 /3- to fuel supply line.
– Secure earth wire of fuel extractor to a bare metal part of the
body.
1. Fuel tank
39
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
– Remove rear seat bench ⇒ General body repairs, interior;
Rep. gr. 72 ; Rear seats; Removing and installing seat bench/
individual seats .
– Unclip cover -1- for flange at retaining tabs -arrows-, using re‐
moval wedge - 3409- .
– Clip sealing grommet -1- downwards from cover -2-.
– Guide cover -2- along wiring harness -3- backwards.
– Release and unplug connector -arrow-.
– Connect test instrument/DSO adapter (5-pin) - VAS 5565- to
connector and fuel delivery unit.
– Connect the remote control - V.A.G 1348/3A- to the measure‐
ment adapter / DSO (5 pin) - VAS 5565- and to battery positive
(+).
Note
The following operation is to make the fuel pump run when the
engine is stopped.
40 Rep. gr.20 - Fuel supply system
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Fuel supply system, petrol engines - Edition 02.2017
– Open tank flap unit -2-.
– Clean area around fuel filler neck.
– Unscrew cap -1- for fuel filler neck.
– Operate remote control - V.A.G 1348/3A- and shut-off tap on
fuel extractor - VAS 5190 A- until fuel tank is empty.
NOTICE
Risk of irreparable damage to fuel pump if allowed to run dry.
– Never allow fuel pump to run »dry«.
1.3.3
Emptying fuel tank if it is more than 3/4
full
Special tools and workshop equipment required
♦ Fuel drainage equipment - VAS 5190 A-
– Make a mark -arrow- at dimension -a- from end of extraction
hose of fuel extractor - VAS 5190 A- .
– Use insulating tape for this.
Rear axle
Vehicles with multi-link rear suspension
Vehicles with trailing arm rear suspension
Vehicles with four-wheel drive
Distance a in mm
945 mm
1,010 mm
960 mm
1. Fuel tank
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– Open tank flap unit -2-.
– Clean area around fuel filler neck.
– Unscrew cap -1- for fuel filler neck.
– Secure earth wire of fuel extractor to a bare metal part of the
body.
– Push extraction hose of extraction unit into fuel tank until pre‐
viously attached marking -arrow- on hose coincides with filler
neck -2-.
– Drain fuel tank via filler neck as far as possible.
Note
♦ There is a flap -1- on the lower end of the fuel filler neck in the
fuel tank which must not be damaged by the extraction hose.
Therefore, only push the hose in as far as the tape marking
-arrow-.
♦ If the extraction hose catches on the non-return valve when
being extracted, do not apply force to pull the extraction hose
out.
♦ In this case, remove the fuel delivery unit and open the non-
return valve manually. Ensure that your arm does not come
into contact with fuel.
– Pull extraction hose out carefully.
Note
♦ When no more fuel is extracted, the tank is emptied just
enough for the sender flange to be opened without danger.
♦ If work has to be done on fuel delivery unit or on fuel gauge
sender , proceed as follows ⇒ page 42 :
1.3.4
Emptying fuel tank if it is less than 3/4 full
42 Rep. gr.20 - Fuel supply system
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
Special tools and workshop
equipment required
♦ Wedge - 3409♦ Wrench - T10202♦ Torque wrench - V.A.G
1332♦ Fuel drainage equipment VAS 5190 A-
Note
Opening the quick-release coupling ⇒ page 68 .
– Secure earth wire of fuel extractor to a bare metal part of the
body.
– Remove rear seat bench ⇒ General body repairs, interior;
Rep. gr. 72 ; Rear seats; Removing and installing seat bench/
individual seats .
– Unclip cover -1- of cover flange from the retaining tabs using
the lever - 3409- -arrows-.
1. Fuel tank
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– Clip sealing grommet -1- downwards from cover -2-.
– Guide cover -2- along wiring harness -3- backwards.
– Release and pull off connector -1- on sealing flange.
– Push tab -2- up in -direction of arrow A-.
– To do this, reach in with your finger between the floor plate
and fuel tank.
– At the same time, carefully pull fuel pump control unit - J538-1- out of mounting -in direction of arrow B- by grasping hold
of wiring harness -3-.
– Guide fuel pump control unit - J538- out towards interior be‐
tween fuel tank and floor panel.
– Place fuel pump control unit - J538- (with wiring harness) to
one side.
– Separate fuel line -1- using sealing flange. Opening the quickrelease coupling ⇒ page 68 .
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
– To do this, loosen lower hose clip.
44 Rep. gr.20 - Fuel supply system
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Fuel supply system, petrol engines - Edition 02.2017
– Open the lock ring with the turning tool - T10202- .
– Carefully lift flange of fuel delivery unit -3-.
– Remove ring -1- and lift flange of fuel delivery unit a little.
– Secure earth wire of fuel extractor to a bare metal part of the
body.
– Insert suction hose of fuel extractor - VAS 5190 A- as far as
possible into fuel tank.
– Extract fuel using fuel extractor - VAS 5190 A- .
If fuel tank needs only to be emptied, install fuel delivery unit
again. ⇒ page 55 .
Specified torques
♦ ⇒ “2.1 Assembly overview - fuel delivery unit, fuel gauge send‐
er”, page 52
1.3.5
Emptying fuel tank with fuel tank more than 3/4 full, engine code CWVA
1. Fuel tank
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Special tools and workshop
equipment required
♦ Wedge - 3409♦ Wrench - T10202♦ Torque wrench - V.A.G
1332♦ Fuel drainage equipment VAS 5190 A-
– Secure earth wire of fuel extractor to a bare metal part of the
body.
– Remove rear seat bench ⇒ General body repairs, interior;
Rep. gr. 72 ; Rear seats; Removing and installing seat bench/
individual seats .
– Unclip cover -1- for flange at retaining tabs -arrows-, using re‐
moval wedge - 3409- .
46 Rep. gr.20 - Fuel supply system
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Fuel supply system, petrol engines - Edition 02.2017
– Clip sealing grommet -1- downwards from cover -2-.
– Guide cover -2- along wiring harness -3- backwards.
– Release and unplug connector -arrow-.
– Disconnect fuel line -1- from flange. Opening the quick-release
coupling ⇒ page 68 .
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
– To do this, loosen lower hose clip.
– Open locking ring using wrench - T10202- .
1. Fuel tank
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– Carefully lift flange of fuel delivery unit -3-.
– Remove gasket -1- and carefully lift up the flange of the fuel
delivery unit slightly more.
– Secure earth wire of fuel extractor to a bare metal part of the
body.
– Insert suction hose of fuel extractor - VAS 5190 A- as far as
possible into fuel tank.
– Extract fuel using fuel extractor - VAS 5190 A- .
If fuel tank needs only to be emptied, install fuel delivery unit
again. ⇒ page 55 .
Specified torques
♦ ⇒ “2.1 Assembly overview - fuel delivery unit, fuel gauge send‐
er”, page 52
1.3.6
Emptying fuel tank with fuel tank less than 3/4 full, vehicles with all-wheel
drive
Special tools and workshop
equipment required
♦ Wedge - 3409♦ Wrench - T10202♦ Fuel drainage equipment VAS 5190 A♦ Torque wrench (40 …
200 Nm) - V.A.G 1332-
48 Rep. gr.20 - Fuel supply system
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Fuel supply system, petrol engines - Edition 02.2017
– Fuel tank: draining ⇒ page 34 .
– Move front seats as far forwards as possible.
– Switch off ignition.
– Remove rear seat bench ⇒ General body repairs, interior;
Rep. gr. 72 ; Rear seats; Removing and installing seat bench/
individual seats .
– Unclip cover -1- for left and right flange from retaining tabs
-arrows- using removal wedge - 3409- .
– Unclip right sealing grommet -1- downwards from cover -2-.
– Guide cover -2- along wiring harness -3- backwards.
– Push tab -2- up in -direction of arrow A-.
– To do this, reach in with your finger between the floor plate
and fuel tank.
– At the same time, carefully pull fuel pump control unit - J538-1- out of mounting -in direction of arrow B- by grasping hold
of wiring harness -3-.
– Guide fuel pump control unit - J538- out towards interior be‐
tween fuel tank and floor panel.
– Place fuel pump control unit - J538- and wiring harness to one
side.
1. Fuel tank
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– Disconnect connectors -1 and 2- as well as fuel line -3- from
flange.
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
– To do this, loosen lower hose clip.
– Open locking ring using wrench - T10202- .
– Carefully lift flange of fuel delivery unit -3-.
– Remove gasket -1- and carefully lift up the flange of the fuel
delivery unit slightly more.
– Secure earth wire of fuel extractor to a bare metal part of the
body.
– Disconnect left connector -arrow-. Lay cover -1- with wiring
harness to one side.
50 Rep. gr.20 - Fuel supply system
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
– Open locking ring using wrench - T10202- .
– Insert suction hose of fuel extractor - VAS 5190 A- as far as
possible into fuel tank.
– Using fuel extractor , extract fuel from both chambers.
If fuel tank needs only to be emptied, install fuel delivery unit
again. ⇒ page 55 .
Specified torques
♦ ⇒ “2.1 Assembly overview - fuel delivery unit, fuel gauge send‐
er”, page 52
1. Fuel tank
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2
Fuel supply unit / fuel supply sender
⇒ “2.1 Assembly overview - fuel delivery unit, fuel gauge sender”,
page 52
⇒ “2.2 Removing and installing fuel delivery unit/fuel supply send‐
er”, page 55
⇒ “3.1 Removing and installing the fuel gauge sender G ”,
page 64
2.1
Assembly overview - fuel delivery unit,
fuel gauge sender
⇒ “2.1.1 Exploded view - fuel delivery unit/fuel supply sender on
vehicles with front-wheel drive”, page 52
⇒ “2.1.2 Exploded view - fuel delivery unit/fuel supply sender on
vehicles with all-wheel drive”, page 54
2.1.1
Exploded view - fuel delivery unit/fuel supply sender on vehicles with frontwheel drive
1 - Fuel delivery unit
❑ With fuel system pres‐
surisation pump - G6- .
❑ With integrated fuel fil‐
ter; cannot be renewed
individually.
❑ With integrated pres‐
sure limiting valve; can‐
not be renewed individ‐
ually.
❑ Checking fuel pump
(electrical test) ⇒ Vehi‐
cle diagnostic tester
❑ Removing and fitting
⇒ page 55
❑ After installing, fill vehi‐
cle with at least 5 litres
of fuel.
2 - Oil seal
❑ seal
❑ Mount dry
3 - Locking ring
❑ Loosen and tighten us‐
ing the wrench T10202❑ 110 Nm
4 - Fuel pump control unit J538❑ Checking in Guided
Fault Finding ⇒ Vehi‐
cle diagnostic tester
❑ Removing and fitting
⇒ page 126
5 - Electric connector
❑ For fuel pump control unit - J538❑ Ensure proper engagement; check if connector is engaged correctly by pulling.
52 Rep. gr.20 - Fuel supply system
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Fuel supply system, petrol engines - Edition 02.2017
6 - Electric connector
❑ For fuel system pressurisation pump - G6- and fuel gauge sender - G❑ Ensure proper engagement; check if connector is engaged correctly by pulling.
7 - Fuel supply line
❑ To engine
❑ Do not kink.
❑ To remove press release tab on connection element
❑ Connections for fuel lines must engage audibly when joined.
❑ Ensure push-fit couplings are secured properly by pulling.
❑ Opening the quick-release couplings ⇒ page 68
8 - Fuel gauge sender - G❑ Checking ⇒ Vehicle diagnostic tester
❑ Removing and fitting ⇒ page 64
Fuel supply unit: assembly position
•
The arrow -3- on the fuel tank must point to marking -2- on
sealing flange -1-.
Fuel lines on fuel delivery unit
1-
Fuel supply line
2. Fuel supply unit / fuel supply sender
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2.1.2
Exploded view - fuel delivery unit/fuel supply sender on vehicles with allwheel drive
1 - Fuel pump control unit J538❑ Check with ⇒ Vehicle di‐
agnostic tester
❑ Removing and fitting
⇒ page 126
2 - Electric connector
❑ For fuel pump control
unit - J538❑ Make sure it is engaged
properly; pull to check
that plug-in connector is
correctly engaged
3 - Electric connector
❑ For fuel system pressur‐
isation pump - G6❑ Make sure it is engaged
properly; pull to check
that plug-in connector is
correctly engaged
4 - Electric connector
❑ For fuel gauge sender G- and fuel supply send‐
er 2 - G169❑ Make sure it is engaged
properly; pull to check
that plug-in connector is
correctly engaged
5 - Locking ring
❑ Loosen and tighten us‐
ing the wrench T10202❑ 110 Nm
6 - Flange
❑ Removing and fitting ⇒ page 65
7 - Oil seal
❑ Must be renewed if removed
❑ Mount dry
8 - Fuel gauge sender 2 - G169❑ Checking (electrical test) ⇒ Vehicle diagnostic tester
❑ Removing and fitting ⇒ page 65
9 - Retainer with suction-jet pump
❑ No replacement part
❑ Welded to fuel tank
❑ Function ⇒ page 129
10 - Fuel gauge sender - G❑ Checking (electrical test) ⇒ Vehicle diagnostic tester
❑ Removing and fitting ⇒ page 64
54 Rep. gr.20 - Fuel supply system
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Fuel supply system, petrol engines - Edition 02.2017
11 - Fuel delivery unit
❑ With the fuel pump (pressurisation pump) - G6❑ With integrated fuel filter
❑ The fuel filter cannot be renewed individually
❑ Carry out electrical test on fuel pump with ⇒ Vehicle diagnostic tester
❑ After installing, fill vehicle with at least 5 litres of fuel.
❑ Removing and fitting ⇒ page 55
12 - Oil seal
❑ Must be renewed if removed
❑ Mount dry
13 - Locking ring
❑ Loosen and tighten using the wrench - T10202❑ 110 Nm
14 - Fuel line
❑ To engine
❑ Do not kink.
❑ To disconnect from flange, press release tab on connection
❑ Connect so it engages audibly
❑ Press in again and then pull to check that plug-in connector is correctly engaged
Fuel supply unit: assembly position
•
The arrow -3- on the fuel tank must line up with the mark -2on the sealing flange -1-.
2.2
Removing and installing fuel delivery
unit/fuel supply sender
⇒ “2.2.1 Removing and installing fuel delivery unit/fuel gauge
sender - vehicles with front-wheel drive”, page 55
⇒ “2.2.2 Removing and installing fuel delivery unit/fuel gauge
sender - vehicles with four-wheel drive”, page 60
2.2.1
Removing and installing fuel delivery
unit/fuel gauge sender - vehicles with
front-wheel drive
Special tools and workshop equipment required
2. Fuel supply unit / fuel supply sender
55
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♦ Wrench - T10202-
♦ Torque wrench (40…200 Nm) - V.A.G 1332-
♦ Wedge - 3409-
Removal:
– Observe the safety measures ⇒ page 1
– Observe rules for cleanliness ⇒ page 4 .
– The fuel tank must not be more than 3/4 full. Therefore, it is
guaranteed that the fuel gauge in the container lies beneath
the fuel delivery unit flange.
– Drain fuel tank ⇒ page 34 .
– Remove rear seat bench ⇒ General body repairs, interior;
Rep. gr. 72 ; Rear seats; Removing and installing seat bench/
individual seats .
56 Rep. gr.20 - Fuel supply system
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Fuel supply system, petrol engines - Edition 02.2017
– Unclip cover -1- for flange at retaining tabs -arrows-, using re‐
moval wedge - 3409- .
– Clip sealing grommet -1- downwards from cover -2-.
– Guide cover -2- along wiring harness -3- backwards.
– Release and pull off connector -1- on sealing flange.
– Separate fuel line -1- using sealing flange. Opening the quickrelease coupling ⇒ page 68 .
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
– To do this, loosen lower hose clip.
2. Fuel supply unit / fuel supply sender
57
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– Open locking ring using wrench - T10202- .
– Carefully lift flange of fuel delivery unit.
– Pull flange -2- slightly out of opening in fuel tank.
– Remove seal -1- from opening in fuel tank.
– Carefully pull out fuel delivery unit with fuel gauge sender - Gthrough opening of fuel tank.
– Turn and tilt it as necessary while doing so.
– When removing the fuel delivery unit, ensure that the float arm
of the fuel gauge sender is not bent.
– Place a cloth underneath the fuel delivery unit to catch any
escaping fuel.
Note
♦ If delivery unit is to be renewed, old delivery unit must be
drained before disposal.
♦ Please observe requirements for disposal.
♦ Check fuel tank for foreign bodies and dirt.
Installation
Installation is in the reverse sequence of removal. The following
must be taken into account:
Note
♦ Opening the quick-release coupling ⇒ page 68 .
♦ Renew seal if damaged.
– Insert dry seal -1- for fuel delivery unit into opening in fuel tank.
– When inserting fuel delivery unit, ensure that fuel gauge send‐
er is not bent.
– Coat inner side of seal -1- with fuel.
– Press down sealing flange -2- against spring force.
– Move flange to installation position.
58 Rep. gr.20 - Fuel supply system
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Fuel supply system, petrol engines - Edition 02.2017
– The arrow -3- on the fuel tank must point to marking -2- on
sealing flange -1-.
– The seal must not be crushed or damaged when installing the
flange.
– Tighten the sealing ring with the wrench - T10202- .
– Push fuel line -1- onto sealing flange until it engages audibly.
– Unplug electrical connector -1- on flange.
– Ensure connectors -1- are firmly seated by pulling.
– Put at least 5 litres of fuel into tank after installing fuel delivery
unit.
WARNING
Risk of explosion of fuel tank caused by fuel pump activation.
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.
Specified torques
♦ ⇒ “2.1 Assembly overview - fuel delivery unit, fuel gauge send‐
er”, page 52
2. Fuel supply unit / fuel supply sender
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2.2.2
Removing and installing fuel delivery
unit/fuel gauge sender - vehicles with
four-wheel drive
Special tools and workshop equipment required
♦ Wrench - T10202-
♦ Wedge - 3409-
Removal:
– The fuel tank must not be more than 3/4 full. Therefore, it is
guaranteed that the fuel gauge in the container lies beneath
the fuel delivery unit flange.
– Drain fuel tank ⇒ page 34 .
– Remove rear seat bench ⇒ General body repairs, interior;
Rep. gr. 72 ; Rear seats; Removing and installing seat bench/
individual seats .
– Disconnect earth wire from battery terminal ⇒ Electrical sys‐
tem; Rep. gr. 27 ; Battery, Disconnecting and connecting
battery .
– Unclip cover -1- for flange (right-side) at retainers -arrows- us‐
ing removal wedge - 3409- .
60 Rep. gr.20 - Fuel supply system
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Fuel supply system, petrol engines - Edition 02.2017
– Clip sealing grommet -1- downwards from cover -2-.
– Guide cover -2- along wiring harness -3- backwards.
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
– Disconnect connectors -1 and 2- as well as fuel line -3- from
flange, and pull them off.
– Open locking ring using wrench - T10202- .
– Carefully lift flange of fuel delivery unit.
– Pull right flange -2- for a short distance out of the opening in
the fuel tank.
– Remove seal -1- from opening in fuel tank.
2. Fuel supply unit / fuel supply sender
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– Disengage the connector -arrow-. Unplug electrical connector
-1- on flange (right-side).
– Carefully pull out fuel delivery unit -1- with fuel gauge sender
- G- -2- through opening in fuel tank by turning and tilting it as
required.
Note
♦ When removing the fuel delivery unit, ensure that the float arm
of the fuel gauge sender is not bent.
♦ If delivery unit is to be renewed, old delivery unit must be
drained before disposal.
♦ Please observe requirements for disposal.
♦ Check fuel tank for foreign bodies and dirt.
62 Rep. gr.20 - Fuel supply system
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Fuel supply system, petrol engines - Edition 02.2017
– Carefully pull fuel lines out of opening in fuel tank.
– Disconnect supply line for suction-jet pump -1- and supply line
-2-.
Installation
Installation is carried out in the reverse order; note the following:
WARNING
Risk of explosion of fuel tank caused by fuel pump activation.
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.
Note
♦ Push on supply line for suction-jet pump and supply line until
it engages audibly.
♦ Insert new seal for fuel delivery unit dry into opening of fuel
tank.
♦ When inserting fuel delivery unit, ensure that fuel gauge send‐
er is not bent.
♦ Coat inner side of seal with fuel.
♦ Check connectors are secured properly by pulling.
– Note installation position of flange when installing
⇒ page 55 .
Specified torques
♦ ⇒ “1.1 Assembly overview - fuel tank”, page 6
♦ ⇒ “2.1 Assembly overview - fuel delivery unit, fuel gauge send‐
er”, page 52
2. Fuel supply unit / fuel supply sender
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3
Sensors
⇒ “3.1 Removing and installing the fuel gauge sender G ”,
page 64
⇒ “3.2 Removing and installing fuel gauge sender 2 G169 ”, page
65
3.1
Removing and installing the fuel gauge
sender - G-
⇒ “3.1.1 Removing and installing fuel gauge sender G , vehicles
with front-wheel drive”, page 64
⇒ “3.1.2 Removing and installing fuel gauge sender G , vehicles
with all-wheel drive”, page 64
3.1.1
Removing and installing fuel gauge
sender - G- , vehicles with front-wheel
drive
Removal:
– Remove fuel delivery unit ⇒ page 55 .
– Note colour assignment of cables -1- for re-installation.
– Release and pull off connectors -1- on sealing flange.
– Disengage and move clear electrical wiring at retainer
-arrow-.
– Release locking lugs -3- and -4- from tabs.
– Pull out fuel gauge sender - G- -2- upwards.
– Bend back the locking hooks of the connectors.
Installation
– Installation is in the reverse sequence of removal. The follow‐
ing must be taken into account:
– Note colour assignment of contacts.
– Pull on the connections to check if they have been connected
correctly.
– Insert fuel gauge sender - G- into the guide on fuel delivery
unit and press downward until it clicks into place.
– Install fuel delivery unit ⇒ page 55 .
•
⇒ “2.1 Assembly overview - fuel delivery unit, fuel gauge send‐
er”, page 52
3.1.2
Removing and installing fuel gauge
sender - G- , vehicles with all-wheel
drive
Removal:
– Remove fuel delivery unit ⇒ page 55 .
– Unplug electrical connector -4- on flange (right-side).
64 Rep. gr.20 - Fuel supply system
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Fuel supply system, petrol engines - Edition 02.2017
– Disengage and move clear electrical wiring at retainer
-arrow-.
– Release locking lugs -1 and 2- from tabs.
– Pull out fuel gauge sender - G- -3- upwards.
Installation
Installation is carried out in the reverse order; note the following:
– Insert fuel gauge sender - G- into the guide on fuel delivery
unit and press downward until it clicks into place.
– Route electrical wiring at fuel delivery unit and clip in.
– Fuel delivery unit: installing ⇒ page 55 .
3.2
Removing and installing fuel gauge
sender 2 - G169-
Special tools and workshop equipment required
♦ Wedge - 3409-
♦ Wrench - T10202-
Removal:
– Observe the safety measures ⇒ page 1
– Observe rules for cleanliness ⇒ page 4 .
– Switch off ignition.
– Remove rear seat bench ⇒ General body repairs, interior;
Rep. gr. 72 ; Rear seats; Removing and installing seat bench/
individual seats .
3. Sensors
65
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Fuel supply system, petrol engines - Edition 02.2017
– Drain the fuel tank ⇒ page 34
– Unclip cover -1- for flange (left-side) at retainers -arrows- using
removal wedge - 3409- .
– Disconnect electrical connector -arrow-. Lay cover -1- with
wiring harness to one side.
– Open locking ring using wrench - T10202- .
– Remove flange and seal at opening in fuel tank.
– Grip through opening in fuel tank. Release connector catches
-arrow-, and disconnect connector -1-.
66 Rep. gr.20 - Fuel supply system
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
– Reach through opening in fuel tank, release retainer catches
-arrows A- and press electrical connector -1- out of retainer
-arrow B-.
– Reach through opening in fuel tank, release retaining tabs
-2- at lugs and at the same time lift out fuel gauge sender 2 G169- -arrow C-.
Installation
Installation is carried out in the reverse order; note the following:
•
⇒ “2.1 Assembly overview - fuel delivery unit, fuel gauge send‐
er”, page 52
Note
♦ Note installation position of flange.
♦ Renew seal ring.
♦ Ensure that the connectors are engaged correctly.
3. Sensors
67
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4
Quick-release couplings
⇒ “4.1 Separating push-on couplings”, page 68
4.1
Separating push-on couplings
Special tools and workshop equipment required
♦ Lever - T10468-
Assignment of the quick-release coupling
Note
♦ The push-on couplings for fuel, vacuum and breather lines are
colour coded. There is either a coloured dot on the plug-in
connector or the release button is of the respective colour
⇒ page 68 .
♦ Connections for fuel lines must engage audibly when joined.
♦ Ensure push-fit couplings are secured properly by pulling.
Colour assignment
Plug-in connector
Colour code on connector
Fuel supply line
Fuel return
Breather
Vacuum
black
Blue
White, beige
green
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
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Version 1
Push-on coupling with release buttons -arrows- on right and left
Opening
It is necessary to counterhold the separating point for fuel -1- in
the engine compartment.
– Insert lever between heat shield and stop - T10468- -arrow- of
fuel line -2- and counterhold.
Continuation for all separating points of fuel system:
– Push the plug connector -1- in the direction of the 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 68
Connections for fuel lines must engage audibly when joined.
– Ensure push-fit couplings are secured properly by pulling.
4. Quick-release couplings
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Version 2
Push-fit coupling with pull-release mechanism -arrow-.
Opening
– Push the plug connector -1- in the direction of the arrow-A-.
– Pull the pull-release mechanism -2- in direction of arrow -B-.
– Pull the plug connector -1- in the direction of the arrow -B- off
the fuel line-3-.
Take note of colour assignment during installation ⇒ page 68
Connections for fuel lines must engage audibly when joined.
– Ensure push-fit couplings are secured properly by pulling.
Version 3
Push-fit coupling with front button -arrowOpening
– Press release button -arrow- and pull push-on connectors off.
Take note of colour assignment during installation ⇒ page 68 .
Connections for fuel lines must engage audibly when joined.
– Ensure push-fit couplings are secured properly by pulling.
Version 4
Push-fit coupling with release button -arrows- on right and left
Opening
– Press push-on coupling in -direction of arrow A-.
– Press release buttons -arrows- and pull push-on coupling off.
Take note of colour assignment during installation ⇒ page 68 .
Connections for fuel lines must engage audibly when joined.
– Ensure push-fit couplings are secured properly by pulling.
70 Rep. gr.20 - Fuel supply system
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Version 5
Push-fit connector with release buttons -arrows- on right and left
Opening
– Press release buttons -arrows- and pull push-on coupling off.
Take note of colour assignment during installation ⇒ page 68 .
Connections for fuel lines must engage audibly when joined.
– Ensure push-fit couplings are secured properly by pulling.
Version 6
Push-fit connector with release buttons -arrows- on right and left
Opening
– Press the lug connector -1- in the direction of the -arrow- and
keep it pressed.
– Press release buttons -arrows- and pull push-on coupling off.
Take note of colour assignment during installation ⇒ page 68 .
Connections for fuel lines must engage audibly when joined.
– Ensure push-fit couplings are secured properly by pulling.
Version 7
Plug-in connector -1- with release buttons -2- on right and left:
Opening
– Press the plug connector -1- in the direction of the arrow -Aand keep it pressed.
– Press the release button -2- in the direction of the arrow -Band pull off the plug connector -1-.
Take note of colour assignment during installation ⇒ page 68 .
Connections for fuel lines must engage audibly when joined.
– Ensure push-fit couplings are secured properly by pulling.
4. Quick-release couplings
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5
Fuel filter
Pressure limiting valve and fuel filter are integrated in fuel delivery
unit and cannot be renewed individually ⇒ page 55 .
72 Rep. gr.20 - Fuel supply system
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6
Activated charcoal filter system:
⇒ “6.1 Exploded view - activated charcoal filter system”,
page 73
⇒ “6.2 Removing and installing activated charcoal filter”,
page 74
⇒ “6.3 Checking the fuel tank breather”, page 75
6.1
Exploded view - activated charcoal filter system
1 - Bleeder hose
❑ to activated charcoal fil‐
ter solenoid valve 1 N80❑ Clipped onto fuel tank.
❑ Checking breather
⇒ page 75
❑ Connection schema
⇒ page 74
❑ To remove press re‐
lease tab on connection
element
❑ Connections for fuel
lines must engage audi‐
bly when joined.
❑ Ensure push-fit cou‐
plings are secured prop‐
erly by pulling.
❑ Opening the quick-re‐
lease couplings
⇒ page 68
2 - Bolt.
❑ 20 Nm
3 - Active carbon filter
❑ Fitting location: At rear
right beneath rear shelf
❑ Removing and fitting
⇒ page 74
❑ Checking breather
⇒ page 75
4 - Bleeder hose
❑ To fuel tank
❑ To remove press re‐
lease tab on connection
element
❑ Connections for fuel lines must engage audibly when joined.
❑ Ensure push-fit couplings are secured properly by pulling.
❑ Opening the quick-release couplings ⇒ page 68
❑ Checking breather ⇒ page 75
❑ Connection schema ⇒ page 74
6. Activated charcoal filter system:
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Illustration of connections on activated charcoal filter
1-
-A- breather connection
2-
-T- connection to fuel tank
3-
-M- to activated charcoal filter solenoid valve 1 - N80-
4-
Protective cap
6.2
Removing and installing activated char‐
coal filter
Removal:
– Observe the safety measures ⇒ page 1
– Observe rules for cleanliness ⇒ page 4 .
– Remove rear right-hand wheel ⇒ Running gear, axles, steer‐
ing; Rep. gr. 44 ; Wheels, tyres .
– Remove rear right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liner; Assembly
overview - rear wheel housing liner .
– Pull breather lines -1- and -2- off activated charcoal filter.
Opening the quick-release coupling ⇒ page 68 .
– Unclip breather pipes from bracket -arrow-.
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– Screw out bolt -1-.
– Press in locking device -3- using screwdriver.
– Pull activated charcoal filter -2- downwards in
-direction of arrow- out of mounting.
Installation
Installation is in the reverse sequence of removal. The following
must be taken into account:
Note
Opening the quick-release coupling ⇒ page 68 .
Specified torques
♦ ⇒ “6.1 Exploded view - activated charcoal filter system”, page
73
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liners; Assembly overview- rear wheel housing liner .
♦ ⇒ Suspension, axles, steering; Rep. gr. 44 ; rims and tyres;
tyre change
6.3
Checking the fuel tank breather
Special tools and workshop equipment required
♦ Hand vacuum pump - VAS 6213-
♦ Pressure tester - VAS 6550-
♦ Connection - VAS 6550/3-
6. Activated charcoal filter system:
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♦ Engine bung set - VAS 6122-
– Observe the safety measures ⇒ page 1
– Observe rules for cleanliness ⇒ page 4 .
– Read event memory ⇒ Vehicle diagnostic tester.
– Switch off ignition.
Check activated charcoal filter solenoid valve 1 - N80- :
– Release and pull off breather line -2-. Opening the quick-re‐
lease coupling ⇒ page 68 .
– Using a connecting nipple - VAS 6213- and a standard hose,
connect hand vacuum pump - VAS 6550/3-1- to line leading
to active charcoal filter system solenoid valve 1 - N80- .
– Move adjuster ring -1- on hand vacuum pump - VAS 6213- to
position -B- to select “pressure”.
– Using the hand vacuum pump - VAS 6213- apply approx. 0.1
bar pressure.
•
If pressure does »not« build up:
– Check line leading to activated charcoal filter solenoid valve 1
- N80- for leaks and damage. If no fault is detected, the sole‐
noid valve - N80- is leaking. Renew solenoid valve - N80- .
•
If pressure builds up:
Activated charcoal filter solenoid valve 1 - N80- is not leaking.
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Checking breather connection on activated charcoal filter
– Release and pull off breather line -2-. Opening the quick-re‐
lease coupling ⇒ page 68 .
– Connect hand vacuum pump - VAS 6213- using adapter - VAS
6550/3-2- to line leading to activated charcoal filter.
– Remove rear right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liner; Assembly
overview - rear wheel housing liner .
– Pull breather line -3- at connection -T- off activated charcoal
filter, and seal connection using suitable workshop equipment.
– Move adjuster ring -1- on hand vacuum pump - VAS 6213- to
position -B- to select “pressure”.
– Actuate the hand vacuum pump - VAS 6213- about 25 times.
•
If »no« pressure builds up:
– Breather connection is OK.
6. Activated charcoal filter system:
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•
If pressure builds up:
– Breather connection -A- on activated charcoal filter is blocked.
Remove breather cap -4-, and check breather connection for
soiling.
Checking activated charcoal filter and breather line for leaks
– Release and pull off breather line -1-. Opening the quick-re‐
lease coupling ⇒ page 68 .
– Connect hand vacuum pump - VAS 6213- using adapter - VAS
6550/3-2- to line leading to activated charcoal filter.
– Remove rear right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liner; Assembly
overview - rear wheel housing liner .
– Pull breather line -3- at connection -T- off activated charcoal
filter, and seal connection using suitable workshop equipment.
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– Remove breather cap from connection -A-, and seal connec‐
tion on activated charcoal filter -2- using a suitable plug -1from engine bung set - VAS 6122- .
– Move adjuster ring -1- on hand vacuum pump - VAS 6213- to
position -B- to select “pressure”.
– Using the hand vacuum pump - VAS 6213- apply approx. 0.1
bar pressure.
•
If pressure builds up:
– Activated charcoal filter and breather line are not leaking.
•
If pressure does »not« build up:
Activated charcoal filter and breather line are leaking. First, check
activated charcoal filter for leaks as follows:
1 - Breather connection -A- is sealed.
2 - Connection -T- is sealed.
6. Activated charcoal filter system:
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– Connect hand vacuum pump - VAS 6213- to connection -Mof activated charcoal filter -1- by means of commercially avail‐
able hose -3-.
– Using the hand vacuum pump - VAS 6213- apply approx. 0.1
bar pressure.
•
If pressure does »not« build up, the activated charcoal filter is
leaking. Check for leaks by hearing, touching or with leak de‐
tector spray.
•
If pressure builds up, the activated charcoal filter is not leaking.
Check breather line.
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7
Accelerator control
⇒ “7.1 Assembly overview - accelerator module”, page 81
⇒ “7.2 Removing and installing accelerator module GX2 ”,
page 82
7.1
Assembly overview - accelerator module
1 - Bolt.
❑ 6 Nm
2 - Electric connector
❑ Make sure it is engaged
properly; pull to check
that plug-in connector is
correctly engaged
3 - Accelerator pedal module GX2❑ Includes the following
parts:
Accelerator position
sender - G79Accelerator position
sender 2 - G185❑ Removing and fitting
⇒ page 82
7. Accelerator control
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7.2
Removing and installing accelerator
module - GX2-
Removal:
– Fold floor covering -1- forwards in -direction of arrow-.
– Release and pull off connector -2- on accelerator pedal mod‐
ule - GX2- .
– Screw out bolt -1-.
– Detach accelerator pedal module -3- from mounting.
Installation
Installation is in the reverse sequence of removal. The following
must be taken into account:
Specified torques
♦ ⇒ “7.1 Assembly overview - accelerator module”, page 81
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8
Fuel pump
⇒ “8.1 Checking fuel system pressurisation pump G6 ”,
page 83
⇒ “8.2 Removing and installing fuel pump control unit J538 ”, page
126
⇒ “8.3 Removing and installing suction-jet pump”, page 129
8.1
Checking fuel system pressurisation
pump - G6-
⇒ “8.1.1 Checking operation and power supply of fuel pump”,
page 83
⇒ “8.1.2 Checking function and voltage supply of the fuel pump,
engine code CWVA”, page 87
⇒ “8.1.3 Checking fuel pressure”, page 90
⇒ “8.1.4 Checking fuel pressure, engine code CWVA”,
page 94
⇒ “8.1.5 Checking holding pressure”, page 98
⇒ “8.1.6 Checking holding pressure, engine code CWVA”,
page 103
⇒ “8.1.7 Checking delivery rate”, page 108
⇒ “8.1.8 Checking fuel delivery rate, engine code CWVA”,
page 114
⇒ “8.1.9 Checking fuel delivery rate, vehicles with four-wheel
drive”, page 120
8.1.1
Checking operation and power supply of
fuel pump
Special tools and workshop equipment required
♦ Wedge - 3409-
8. Fuel pump
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♦ Multimeter e.g. hand-held multimeter - V.A.G 1526E-
♦ Auxiliary measuring set - V.A.G 1594C-
♦ Vehicle diagnostic and service information system
Test requirements:
•
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.
Checking process:
Note
Function of fuel pump is checked using final control diagnosis.
– Observe the safety measures ⇒ page 1
– Observe rules for cleanliness ⇒ page 4 .
– Connect vehicle diagnostic tester .
– Switch ignition on.
– Select final control diagnosis for fuel pump in vehicle self-di‐
agnosis program.
The fuel pump should start running, first slowly and then gradually
up to full power.
84 Rep. gr.20 - Fuel supply system
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Note
♦ The fuel pump runs very quietly.
♦ If the final control diagnosis is to be carried out several times
in succession, it may be necessary to start the engine briefly
before repeating the final control diagnosis.
– Switch off ignition.
If the fuel pump does not start:
– Remove bench seat ⇒ General body repairs, interior; Rep. gr.
72 ; Rear seat; Removing and installing bench seat / individual
seats .
– Unclip cover -1- for flange at retaining tabs -arrows-, using re‐
moval wedge - 3409- .
– Clip sealing grommet -1- downwards from cover -2-.
– Guide cover -2- along wiring harness -3- backwards.
– Push tab -2- up in -direction of arrow A-.
– To do this, reach in with your finger between the floor plate
and fuel tank.
– At the same time, carefully pull fuel pump control unit - J538-1- out of mounting in direction of arrow -B- by grasping hold
of wiring harness -3-.
– Guide fuel pump control unit - J538- out towards interior be‐
tween fuel tank and floor panel.
– Ensure that connector on fuel pump control unit - J538- is fitted
securely by pulling connector without pressing catch. If the
plug connector had not been connected properly, the func‐
tional inspection of the fuel pump must be repeated.
– Release and pull off connector from fuel pump control unit J538- .
– Check contacts on connector and on fuel pump control unit J538- for damage.
8. Fuel pump
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– Check voltage supply between contacts -3- and -4- using mul‐
timeter ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
– Use auxiliary measuring set - V.A.G 1594C- to do this.
– Switch ignition on.
•
Specification: approx. battery voltage
If specification is not obtained:
– Locate and rectify open circuit using current flow diagram
⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐
cations.
If result matches specification:
– Check that connector -1- is fitted securely by pulling connector
without pressing catch. If the plug connector had not been
connected properly, the functional inspection of the fuel pump
must be repeated.
– Release push-fit connector -1- and pull off.
– Check contacts on plug and on fuel delivery unit for damage.
– Check wiring harness between fuel pump control unit - J538and fuel delivery unit ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.
If specification is attained on vehicles with four-wheel drive:
– Check that connector -1- is fitted securely by pulling connector
without pressing catch. If the plug connector had not been
connected properly, the functional inspection of the fuel pump
must be repeated.
– Release push-fit connector -1- and pull off.
– Check contacts on plug and on fuel delivery unit for damage.
– Check wiring harness between fuel pump control unit - J538and fuel delivery unit ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.
If no fault is found:
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
– Drain the fuel tank ⇒ page 34
– Pull fuel line -1- out of sealing flange. Opening the quick-re‐
lease coupling ⇒ page 68 .
86 Rep. gr.20 - Fuel supply system
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Continued for all vehicles:
– Open locking ring using wrench - T10202- .
– Check that electrical wires between flange and fuel pump are
connected.
– Check electrical wiring between flange and fuel pump for con‐
tinuity using an ohmmeter.
– Check contacts for damage.
If there is cable integrity:
– Fuel pump is defective, renew fuel delivery unit ⇒ page 55 .
8.1.2
Checking function and voltage supply of
the fuel pump, engine code CWVA
Special tools and workshop equipment required
♦ Wedge - 3409-
8. Fuel pump
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♦ Multimeter e.g. hand-held multimeter - V.A.G 1526E-
♦ Auxiliary measuring set - V.A.G 1594C-
♦ Vehicle diagnostic and service information system
Test requirements:
•
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.
Checking process:
Note
Function of fuel pump is checked using final control diagnosis.
– Observe the safety measures ⇒ page 1
– Observe rules for cleanliness ⇒ page 4 .
88 Rep. gr.20 - Fuel supply system
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– Connect the vehicle diagnosis tester -1- in the following way:
– Connect diagnosis cable connector -2- to diagnostic connec‐
tion in driver footwell.
– Switch ignition on.
– Select final control diagnosis for fuel pump in vehicle self-di‐
agnosis program.
The fuel pump should start running, first slowly and then gradually
up to full power.
Note
♦ The fuel pump runs very quietly.
♦ If the final control diagnosis is to be carried out several times
in succession, it may be necessary to start the engine briefly
before repeating the final control diagnosis.
– Switch off ignition.
If the fuel pump does not start:
– Remove bench seat ⇒ General body repairs, interior; Rep. gr.
72 ; Rear seat; Removing and installing bench seat / individual
seats .
– Unclip cover -1- for flange at retaining tabs -arrows-, using re‐
moval wedge - 3409- .
– Unclip cover -1- for flange (right-side) at retainers -arrows- us‐
ing removal wedge - 3409- .
– Clip sealing grommet -1- downwards from cover -2-.
– Guide cover -2- along wiring harness -3- backwards.
8. Fuel pump
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– Check that plug connector -arrow- is fitted securely by pulling
the plug connector without pressing the catch.
– If connector was not inserted correctly, repeat final control di‐
agnosis of fuel pump.
– Release and unplug connector -arrow-.
– Check contacts on plug and on fuel delivery unit for damage.
– Connect test instrument/DSO adapter (5-pin) - VAS 5565- to
connector and fuel delivery unit.
– Connect multimeter to cables -1- and -5- of test instrument
adapter/DSO (5-pin) - VAS 5565- .
– Switch ignition on.
•
Specification: approx. battery voltage
If specification is not obtained:
– Locate and rectify open circuit using current flow diagram
⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐
cations.
If no fault is found:
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
– Drain the fuel tank ⇒ page 34
– Pull fuel line -1- out of sealing flange. Opening the quick-re‐
lease coupling ⇒ page 68 .
Continued for all vehicles:
– Open locking ring using wrench - T10202- .
– Check that electrical wires between flange and fuel pump are
connected.
– Check contacts for damage.
If there is cable integrity:
– Fuel pump is defective, renew fuel delivery unit ⇒ page 55 .
8.1.3
Checking fuel pressure
90 Rep. gr.20 - Fuel supply system
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Fuel supply system, petrol engines - Edition 02.2017
Special tools and workshop
equipment required
♦ Wedge - 3409♦ Pressure gauge - VAS
6550♦ Connecting wire - VAS
6550/3-3♦ Connecting wire - VAS
6550/3-4♦ Vehicle diagnostic and
service information system
Prerequisites:
•
Voltage supply okay ⇒ page 83 .
– Observe the safety measures ⇒ page 1
– Observe rules for cleanliness ⇒ page 4 .
– Pull off supply line -1-. Opening the quick-release coupling
⇒ page 68 .
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
– Collect escaping fuel with a cleaning cloth.
8. Fuel pump
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– Connect hose - VAS 6550/1- to connection -A- of pressure
tester - VAS 6550- .
– Connect hose - VAS 6550/1- to fuel supply line -1- leading to
engine.
– Connect hose - VAS 6550/2- to connection -B- of pressure
tester - VAS 6550- .
– Use hose - VAS 6550- to connect fuel line leading to fuel tank
with pressure tester - VAS 6550/2- .
– Ensure push-fit couplings are secured properly by pulling.
– Make sure that the radiator shut-off tap -C- is connected to the
pressure gauge -1-.
– The cut-off valves -A- and -B- are open on the pressure gauge
-1-.
– Connect vehicle diagnostic tester .
– Select final control diagnosis for fuel pump in vehicle self-di‐
agnosis program.
Note
♦ The fuel pump is now actuated to build up fuel pressure.
♦ If the final control diagnosis is to be carried out several times
in succession, it may be necessary to start the engine briefly
before repeating the final control diagnosis.
– Read the fuel pressure on the pressure gauge.
•
Specification: 4.0 … 7.0 bar
If the fuel pressure is correct, check the retention pressure
⇒ page 98 .
If specification is exceeded:
– Pressure limiting valve in fuel delivery unit is defective.
– Renew the fuel delivery unit ⇒ page 55 .
If specification is not obtained:
Proceed as follows to check fuel pressure at fuel delivery unit:
– Remove rear seat bench ⇒ General body repairs, interior;
Rep. gr. 72 ; Rear seats; Removing and installing seat bench/
individual seats .
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– Unclip cover -1- for flange at retaining tabs -arrows-, using re‐
moval wedge - 3409- .
– Clip sealing grommet -1- downwards from cover -2-.
– Guide cover -2- along wiring harness -3- backwards.
– Push tab -2- up in -direction of arrow A-.
– To do this, reach in with your finger between the floor plate
and fuel tank.
– At the same time, carefully pull fuel pump control unit -1- on
its wiring harness -3- in direction of arrow -B- out of its holder.
– Guide fuel pump control unit - J538- out towards interior be‐
tween fuel tank and floor panel.
– Place fuel pump control unit - J538- (with connector still con‐
nected) to one side.
– Pull fuel line -1- out of sealing flange. Opening the quick-re‐
lease coupling ⇒ page 68 .
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
8. Fuel pump
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– Connect pressure tester - VAS 6550- with hose - VAS
6550/3-4- to fuel delivery unit -1-.
– Connect pressure tester - VAS 6550/3-3- and fuel supply line
-2- by means of hose - VAS 6550- .
– Ensure push-fit couplings are secured properly by pulling.
– Make sure that the radiator shut-off tap -C- is connected to the
pressure gauge -1-.
– The cut-off valves -A- and -B- are open on the pressure gauge
-1-.
– Repeat the diagnosis of the regulating elements to build up the
fuel pressure.
If result matches specification:
– Check to ensure that there are no crushing points (kinks) or
blockages in the fuel pipes.
– Check fuel line for leaks and damage.
If specification is not obtained:
– Remove fuel delivery unit ⇒ page 55 and check for contami‐
nation.
– Check that all hoses are connected.
– Check to ensure that there are no crushing points (kinks) or
blockages in the fuel pipes.
– Check fuel lines for leaks and damage.
If no fault is found:
– Fuel pump is defective, renew fuel delivery unit ⇒ page 55 .
8.1.4
Checking fuel pressure, engine code CWVA
94 Rep. gr.20 - Fuel supply system
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Fuel supply system, petrol engines - Edition 02.2017
Special tools and workshop
equipment required
♦ Wedge - 3409♦ Pressure gauge - VAS
6550♦ Connecting wire - VAS
6550/3-3♦ Connecting wire - VAS
6550/3-4♦ Vehicle diagnostic and
service information system
Prerequisites:
•
Voltage supply okay ⇒ page 83 .
– Observe the safety measures ⇒ page 1
– Observe rules for cleanliness ⇒ page 4 .
– Pull off supply line -1-. Opening the quick-release coupling
⇒ page 68 .
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
– Collect escaping fuel with a cleaning cloth.
8. Fuel pump
95
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
– Connect hose - VAS 6550/1- to connection -A- of pressure
tester - VAS 6550- .
– Connect hose - VAS 6550/1- to fuel supply line -1- leading to
engine.
– Connect hose - VAS 6550/2- to connection -B- of pressure
tester - VAS 6550- .
– Use hose - VAS 6550- to connect fuel line leading to fuel tank
with pressure tester - VAS 6550/2- .
– Ensure push-fit couplings are secured properly by pulling.
– Make sure that the radiator shut-off tap -C- is connected to the
pressure gauge -1-.
– The cut-off valves -A- and -B- are open on the pressure gauge
-1-.
– Connect vehicle diagnostic tester .
– Select final control diagnosis for fuel pump in vehicle self-di‐
agnosis program.
Note
♦ The fuel pump is now actuated to build up fuel pressure.
♦ If the final control diagnosis is to be carried out several times
in succession, it may be necessary to start the engine briefly
before repeating the final control diagnosis.
– Read the fuel pressure on the pressure gauge.
•
Specification: 4.0 bar
If the fuel pressure is correct, check the retention pressure
⇒ page 98 .
If specification is exceeded:
– Pressure limiting valve in fuel delivery unit is defective.
– Renew the fuel delivery unit ⇒ page 55 .
If specification is not obtained:
Proceed as follows to check fuel pressure at fuel delivery unit:
– Remove rear seat bench ⇒ General body repairs, interior;
Rep. gr. 72 ; Rear seats; Removing and installing seat bench/
individual seats .
96 Rep. gr.20 - Fuel supply system
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Fuel supply system, petrol engines - Edition 02.2017
– Unclip cover -1- for flange at retaining tabs -arrows-, using re‐
moval wedge - 3409- .
– Clip sealing grommet -1- downwards from cover -2-.
– Guide cover -2- along wiring harness -3- backwards.
– Pull fuel line -1- out of sealing flange. Opening the quick-re‐
lease coupling ⇒ page 68 .
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
– Connect pressure tester - VAS 6550- with hose - VAS
6550/3-4- to fuel delivery unit -1-.
– Connect pressure tester - VAS 6550/3-3- and fuel supply line
-2- by means of hose - VAS 6550- .
– Ensure push-fit couplings are secured properly by pulling.
8. Fuel pump
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– Make sure that the radiator shut-off tap -C- is connected to the
pressure gauge -1-.
– Shut-off valves -A- and -B- on pressure tester -1- are open.
– Repeat the diagnosis of the regulating elements to build up the
fuel pressure.
If result matches specification:
– Check to ensure that there are no crushing points (kinks) or
blockages in the fuel pipes.
– Check fuel line for leaks and damage.
If specification is not obtained:
– Remove fuel delivery unit ⇒ page 55 and check for contami‐
nation.
– Check that all hoses are connected.
– Check to ensure that there are no crushing points (kinks) or
blockages in the fuel pipes.
– Check fuel lines for leaks and damage.
If no fault is found:
– Fuel pump is defective, renew fuel delivery unit ⇒ page 55 .
8.1.5
Checking holding pressure
98 Rep. gr.20 - Fuel supply system
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
Special tools and workshop
equipment required
♦ Pressure gauge - VAS
6550♦ Wedge - 3409♦ Connecting wire - VAS
6550/3-3♦ Connecting wire - VAS
6550/3-4♦ Vehicle diagnostic and
service information system
– Observe the safety measures ⇒ page 1
– Observe rules for cleanliness ⇒ page 4 .
– Pull off supply line -1-. Opening the quick-release coupling
⇒ page 68 .
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
– Collect escaping fuel with a cleaning cloth.
•
Fuel pressure OK and pressure tester - VAS 6550- connected.
Check fuel pressure ⇒ page 90 .
8. Fuel pump
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– Connect fuel line from fuel tank to shut-off tap -B- of pressure
tester - VAS 6550/2- by means of hose - VAS 6550- .
– Connect fuel line leading to engine -1- to shut-off tap -A- of
pressure tester - VAS 6550/1- by means of hose - VAS 6550- .
Checking process:
– Connect vehicle diagnostic tester .
– Select final control diagnosis for fuel pump in vehicle self-di‐
agnosis program.
Note
♦ The fuel pump is now actuated to build up fuel pressure.
♦ If the final control diagnosis is to be carried out several times
in succession, it may be necessary to start the engine briefly
before repeating the final control diagnosis.
– Read the fuel pressure on the pressure gauge.
•
Specification: ≥ 4.0 bar
– End self-diagnosis and switch ignition off.
– Observe pressure drop on tester. After 10 minutes the pres‐
sure must not drop below 3.0 bar.
If the pressure drops:
– Check fuel lines in engine compartment for leaks and damage.
100 Rep. gr.20 - Fuel supply system
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Fuel supply system, petrol engines - Edition 02.2017
If no fault is found:
– Make sure that the radiator shut-off tap -C- is connected to the
pressure gauge -1-.
– The cut-off valves -A- and -B- are open on the pressure gauge
-1-.
– Actuate fuel pump with final control diagnosis to build up fuel
pressure.
– After pressure has built up, close shut-off tap -A- of pressure
tester immediately. The lever must point horizontally in the
flow direction.
If the pressure drops again (leak on fuel tank side):
Check the residual pressure in the fuel delivery unit. Proceed as
follows ⇒ page 101 :
If the pressure does not drop now (leak on engine side):
Note
Search for the leak on the engine side. Check the retention pres‐
sure again. Now close cut-off valve -B- to check whether there is
in fact a leak on the engine side.
– If there is a leak on the engine side visually check tightness of
the fuel pipe and the high-pressure pump.
If no fault can be determined, check the injectors for leaks:
– Remove the spark plugs.
– Open shut-off valves -A- and -B-. Actuate fuel pump with final
control diagnosis.
– Check through spark plug holes whether fuel has collected on
the piston crown due to a leaking injector.
Checking residual pressure on fuel delivery unit:
– Remove rear seat bench ⇒ General body repairs, interior;
Rep. gr. 72 ; Rear seats; Removing and installing seat bench/
individual seats .
– Unclip cover -1- for flange at retaining tabs -arrows-, using re‐
moval wedge - 3409- .
8. Fuel pump
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– Clip sealing grommet -1- downwards from cover -2-.
– Guide cover -2- along wiring harness -3- backwards.
– Push tab -2- up in -direction of arrow A-.
– To do this, reach in with your finger between the floor plate
and fuel tank.
– At the same time, carefully pull fuel pump control unit -1- on
its wiring harness -3- in direction of arrow -B- out of its holder.
– Guide fuel pump control unit - J538- out towards interior be‐
tween fuel tank and floor panel.
– Place fuel pump control unit - J538- (with connector still con‐
nected) to one side.
– Pull fuel line -1- out of sealing flange. Opening the quick-re‐
lease coupling ⇒ page 68 .
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
– Connect pressure tester - VAS 6550- with hose - VAS
6550/3-4- to fuel delivery unit -1-.
– Connect pressure tester - VAS 6550/3-3- to fuel line -2- by
means of hose - VAS 6550- .
– Ensure push-fit couplings are secured properly by pulling.
102 Rep. gr.20 - Fuel supply system
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Fuel supply system, petrol engines - Edition 02.2017
– Make sure that the radiator shut-off tap -C- is connected to the
pressure gauge -1-.
– The cut-off valves -A- and -B- are open on the pressure gauge
-1-.
– Actuate fuel pump with final control diagnosis to build up fuel
pressure.
– After pressure has been built up, immediately close the shutoff valve -B- on the pressure gauge. The lever must point
horizontally in the flow direction.
– Repeat holding pressure check ⇒ page 100 .
If the pressure does not drop any more:
– Test fuel line for tightness.
If the pressure drops again:
– Remove fuel delivery unit -1- ⇒ page 55 .
– Check that all hose connections are connected.
– Check fuel lines for leaks and damage.
If no fault is found:
– If the pressure retention valve in the fuel delivery unit is de‐
fective: Renew the fuel delivery unit ⇒ page 55 .
8.1.6
Checking holding pressure, engine code CWVA
8. Fuel pump
103
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Special tools and workshop
equipment required
♦ Pressure gauge - VAS
6550♦ Wedge - 3409♦ Connecting wire - VAS
6550/3-3♦ Connecting wire - VAS
6550/3-4♦ Vehicle diagnostic and
service information system
– Observe the safety measures ⇒ page 1
– Observe rules for cleanliness ⇒ page 4 .
– Pull off supply line -1-. Opening the quick-release coupling
⇒ page 68 .
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
– Collect escaping fuel with a cleaning cloth.
•
Fuel pressure OK and pressure tester - VAS 6550- connected.
Check fuel pressure ⇒ page 94 .
104 Rep. gr.20 - Fuel supply system
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– Connect fuel line from fuel tank to shut-off tap -B- of pressure
tester - VAS 6550/2- by means of hose - VAS 6550- .
– Connect fuel line leading to engine -1- to shut-off tap -A- of
pressure tester - VAS 6550/1- by means of hose - VAS 6550- .
Checking process:
– Connect vehicle diagnostic tester .
– Select final control diagnosis for fuel pump in vehicle self-di‐
agnosis program.
Note
♦ The fuel pump is now actuated to build up fuel pressure.
♦ If the final control diagnosis is to be carried out several times
in succession, it may be necessary to start the engine briefly
before repeating the final control diagnosis.
– Read the fuel pressure on the pressure gauge.
•
Specification: ≥ 4.0 bar
– End self-diagnosis and switch ignition off.
– Observe pressure drop on tester. After 10 minutes, the pres‐
sure must not drop by more than 1.0 bar.
If the pressure drops:
– Check fuel lines for leaks and damage.
8. Fuel pump
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If no fault is found:
– Make sure that the radiator shut-off tap -C- is connected to the
pressure gauge -1-.
– Shut-off valves -A- and -B- on pressure tester -1- are open.
– Actuate fuel pump with final control diagnosis to build up fuel
pressure.
– After pressure has built up, close shut-off tap -A- of pressure
tester immediately. The lever must point horizontally in the
flow direction.
If the pressure drops again (leak on fuel tank side):
Check the residual pressure in the fuel delivery unit. Proceed as
follows ⇒ page 101 :
If the pressure does not drop now (leak on engine side):
Note
Search for the leak on the engine side. Check the retention pres‐
sure again. Now close cut-off valve -B- to check whether there is
in fact a leak on the engine side.
If there is a leak on engine side:
– Check surfaces of fuel lines for leaks.
– Check surfaces of fuel rail and injectors for leaks ⇒ Rep. gr.
24 ; Injectors; Assembly overview - fuel rail with injectors .
If no fault is found:
– Check injectors for leaks ⇒ Rep. gr. 24 ; Injectors; Checking
injectors .
Checking residual pressure on fuel delivery unit:
– Remove rear seat bench ⇒ General body repairs, interior;
Rep. gr. 72 ; Rear seats; Removing and installing seat bench/
individual seats .
– Unclip cover -1- for flange at retaining tabs -arrows-, using re‐
moval wedge - 3409- .
106 Rep. gr.20 - Fuel supply system
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Fuel supply system, petrol engines - Edition 02.2017
– Clip sealing grommet -1- downwards from cover -2-.
– Guide cover -2- along wiring harness -3- backwards.
– Pull fuel line -1- out of sealing flange. Opening the quick-re‐
lease coupling ⇒ page 68 .
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
– Connect pressure tester - VAS 6550- with hose - VAS
6550/3-4- to fuel delivery unit -1-.
– Connect pressure tester - VAS 6550/3-3- to fuel line -2- by
means of hose - VAS 6550- .
– Ensure push-fit couplings are secured properly by pulling.
8. Fuel pump
107
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– Make sure that the radiator shut-off tap -C- is connected to the
pressure gauge -1-.
– The cut-off valves -A- and -B- are open on the pressure gauge
-1-.
– Actuate fuel pump with final control diagnosis to build up fuel
pressure.
– After pressure has been built up, immediately close the shutoff valve -B- on the pressure gauge. The lever must point
horizontally in the flow direction.
– Repeat holding pressure check ⇒ page 105 .
If the pressure does not drop any more:
– Test fuel line for tightness.
If the pressure drops again:
– Remove fuel delivery unit -1- ⇒ page 55 .
– Check that all hose connections are connected.
– Check fuel lines for leaks and damage.
If no fault is found:
– If the pressure retention valve in the fuel delivery unit is de‐
fective: Renew the fuel delivery unit ⇒ page 55 .
8.1.7
Checking delivery rate
108 Rep. gr.20 - Fuel supply system
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
Special tools and workshop
equipment required
♦ Wedge - 3409♦ Remote control for V. A . G.
1348 - V.A.G 1348/3A♦ Multimeter e.g. hand-held
multimeter - V.A.G 1526E♦ Test instrument adapter/
DSO (5-pin) - VAS 5565♦ Pressure tester - VAS
6550♦ Vehicle diagnostic and
service information system
♦ Connecting wire - VAS
6550/3-3♦ Connecting wire - VAS
6550/3-4♦ Overpressure control valve
- VAS 6550/4♦ Measuring container, ca‐
pacity ≥ 3 litre
8. Fuel pump
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♦ Auxiliary measuring set - V.A.G 1594C-
Carry out the following working steps:
Checking fuel delivery rate in engine compartment, quick test:
Note
The fuel deliver rate will initially be checked in the engine com‐
partment using the guided function “Checking fuel delivery rate,
quick test”. If the minimum delivery rate is not achieved, a second
measurement must be carried out on the flange of the fuel supply
unit.
– Connect vehicle diagnostic tester .
– Start Guided Functions.
– Select function: Check fuel delivery rate; quick test.
– Follow instructions on vehicle diagnosis tester .
110 Rep. gr.20 - Fuel supply system
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Fuel supply system, petrol engines - Edition 02.2017
If specification is not obtained:
– Open tank flap unit -2-.
– Clean area around fuel filler neck.
– Unscrew cap -1- for fuel filler neck.
– Check fuel delivery rate, repeat quick test ⇒ page 110 .
If result matches specification:
– Check fuel tank breather ⇒ page 75 .
If specification is not obtained:
– Check to ensure that there are no crushing points (kinks) or
blockages in the fuel pipes.
– Check fuel lines for leaks and damage.
If no fault is found:
Proceed as follows to check fuel delivery rate at fuel delivery unit:
Checking fuel delivery rate on fuel delivery unit:
Note
♦ Opening the quick-release coupling ⇒ page 68 .
♦ When malfunctions occur in the dynamic behaviour of the ve‐
hicle with a fuel tank filled to max. 1/4, the fuel supply quantity
must be tested at a fuel tank filling level of 1/4 or less.
•
Speedometer must be okay. ⇒ page 83
•
Fuel pressure OK ⇒ page 90 .
•
The battery voltage must be at least 11.5 V, if necessary con‐
nect a battery charger ⇒ Electrical system; Rep. gr. 27 ;
Battery; Charging battery .
•
Fuel pump control unit - J538- OK ⇒ Vehicle diagnostic tester.
– Observe the safety measures ⇒ page 1
– Observe rules for cleanliness ⇒ page 4 .
– Connect battery charger ⇒ Electrical system; Rep. gr. 27 ;
Battery; Charging battery .
– Remove rear seat bench ⇒ General body repairs, interior;
Rep. gr. 72 ; Rear seats; Removing and installing seat bench/
individual seats .
– Unclip cover -1- for flange at retaining tabs -arrows-, using re‐
moval wedge - 3409- .
8. Fuel pump
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– Clip sealing grommet -1- downwards from cover -2-.
– Guide cover -2- along wiring harness -3- backwards.
– Push tab -2- up in -direction of arrow A-.
– To do this, reach in with your finger between the floor plate
and fuel tank.
– At the same time, carefully pull fuel pump control unit -1- on
its wiring harness -3- in direction of arrow -B- out of its holder.
– Guide fuel pump control unit - J538- out towards interior be‐
tween fuel tank and floor panel.
– Place fuel pump control unit - J538- (with connector still con‐
nected) to one side.
– Check that connector -1- is fitted securely by pulling connector
without pressing catch. Malfunctions may arise when the con‐
nector has not been inserted correctly.
– Release push-fit connector -1- and pull off.
– Check contacts on plug and on fuel delivery unit for damage.
– If fitted, unclip connector -2- from retainer.
– Connect test instrument adapter/DSO (5-pin) - VAS 5565- to
fuel delivery unit -1-.
– Connect remote control - V.A.G 1348/3A- to adapter - VAS
5565- and to battery positive terminal in engine compartment.
– Connect connection -5- (yellow) of test instrument adapter/
DSO (5-pin) - VAS 5565- to battery negative terminal using
suitable workshop equipment -3-.
– Also use auxiliary measuring set - V.A.G 1594C- for this pur‐
pose.
Note
The following operation is to make the fuel pump run when the
engine is stopped.
112 Rep. gr.20 - Fuel supply system
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Fuel supply system, petrol engines - Edition 02.2017
– Pull fuel line -1- out of sealing flange. Opening the quick-re‐
lease coupling ⇒ page 68 .
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
– The quantity of fuel delivered by the fuel pump is dependent
upon battery voltage. Therefore, also connect multimeter to
outputs -1- and -5- of test instrument/DSO adapter (5-pin) VAS 5565- .
– Connect multimeter with auxiliary measuring set - V.A.G
1594C- .
– Connect pressure tester - VAS 6550- with hose - VAS
6550/3-4- to fuel delivery unit -1-.
– Connect hose - VAS 6550/3-4- to shut-off tap -A-.
– Connect pressure regulating valve - VAS 6550/4- to connec‐
tion -B- of pressure tester - VAS 6550– Hold end of hose of pressure regulating valve - VAS 6550/4in measuring container.
– Make sure that the radiator shut-off tap -C- is connected to the
pressure gauge -1-.
– The cut-off valves -A- and -B- are open on the pressure gauge
-1-.
– Operate the remote control - V.A.G 1348/3A- .
Note
The fuel system pressurisation pump - G6- will be actuated.
8. Fuel pump
113
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– Adjust the pressure regulating valve -arrow- with the adjust‐
ment wheel to a counter pressure of 4.0 bar.
– From this point on do not change position of adjuster wheel
anymore.
– Drain measuring container.
– Press remote control for 60 seconds whilst measuring voltage
at fuel pump.
– Compare delivered quantity of fuel with specification indicated
in chart.
Name of axis
Control unit
Minimum delivery rate
Voltage at fuel pump with en‐
gine not running and pump run‐
ning.
cm
Volt
Readout example:
During the test a voltage of 10.5 volts is measured. This results
in a minimum delivery rate of approx. 1200 cm in 60 seconds.
If result matches specification:
– Check to ensure that there are no crushing points (kinks) or
blockages in the fuel pipes.
– Check fuel lines for leaks and damage.
If specification is not obtained:
– Remove fuel delivery unit ⇒ page 55 .
– Check filter strainer for soiling.
– Check that all hose connections are properly connected to fuel
delivery unit -1-.
– Check to ensure that there are no crushing points (kinks) or
blockages in the fuel pipes.
– Check fuel lines for leaks and damage.
If no fault is found:
– Renew the fuel delivery unit ⇒ page 55 .
8.1.8
Checking fuel delivery rate, engine code CWVA
114 Rep. gr.20 - Fuel supply system
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
Special tools and workshop
equipment required
♦ Wedge - 3409♦ Remote control for V. A . G.
1348 - V.A.G 1348/3A♦ Multimeter e.g. hand-held
multimeter - V.A.G 1526E♦ Test instrument adapter/
DSO (5-pin) - VAS 5565♦ Pressure gauge - VAS
6550♦ Vehicle diagnostic and
service information system
♦ Connecting wire - VAS
6550/3-3♦ Connecting wire - VAS
6550/3-4♦ Overpressure control valve
- VAS 6550/4♦ Measuring container, ca‐
pacity ≥ 3 litre
8. Fuel pump
115
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Fuel supply system, petrol engines - Edition 02.2017
♦ Auxiliary measuring set - V.A.G 1594C-
Carry out the following working steps:
Checking fuel delivery rate in engine compartment, quick test:
Note
The fuel deliver rate will initially be checked in the engine com‐
partment using the guided function “Checking fuel delivery rate,
quick test”. If the minimum delivery rate is not achieved, a second
measurement must be carried out on the flange of the fuel supply
unit.
– Connect the vehicle diagnosis and service information sys‐
tem .
– Start Guided Functions.
– Select function: Check fuel delivery rate; quick test.
– Follow instructions on vehicle diagnosis tester .
116 Rep. gr.20 - Fuel supply system
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
If specification is not obtained:
– Open tank flap unit -2-.
– Clean area around fuel filler neck.
– Unscrew cap -1- for fuel filler neck.
– Check fuel delivery rate, repeat quick test ⇒ page 110 .
If result matches specification:
– Check fuel tank breather ⇒ page 75 .
If specification is not obtained:
– Check to ensure that there are no crushing points (kinks) or
blockages in the fuel pipes.
– Check fuel lines for leaks and damage.
If no fault is found:
Proceed as follows to check fuel delivery rate at fuel delivery unit:
Checking fuel delivery rate on fuel delivery unit:
Note
♦ Opening the quick-release coupling ⇒ page 68 .
♦ When malfunctions occur in the dynamic behaviour of the ve‐
hicle with a fuel tank filled to max. 1/4, the fuel supply quantity
must be tested at a fuel tank filling level of 1/4 or less.
•
Speedometer must be okay. ⇒ page 83
•
Fuel pressure OK ⇒ page 90 .
•
The battery voltage must be at least 11.5 V, if necessary con‐
nect a battery charger ⇒ Electrical system; Rep. gr. 27 ;
Battery; Charging battery .
•
Fuel pump control unit - J538- OK ⇒ Vehicle diagnostic tester.
– Observe the safety measures ⇒ page 1
– Observe rules for cleanliness ⇒ page 4 .
– Connect battery charger ⇒ Electrical system; Rep. gr. 27 ;
Battery; Charging battery .
– Remove rear seat bench ⇒ General body repairs, interior;
Rep. gr. 72 ; Rear seats; Removing and installing seat bench/
individual seats .
– Unclip cover -1- for flange at retaining tabs -arrows-, using re‐
moval wedge - 3409- .
8. Fuel pump
117
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– Clip sealing grommet -1- downwards from cover -2-.
– Guide cover -2- along wiring harness -3- backwards.
– Check that connector -1- is fitted securely by pulling connector
without pressing catch. Malfunctions may arise when the con‐
nector has not been inserted correctly.
– Release push-fit connector -1- and pull off.
– Check contacts on plug and on fuel delivery unit for damage.
– Connect test instrument/DSO adapter (5-pin) - VAS 5565- to
connector and fuel delivery unit.
– Connect remote control - V.A.G 1348/3A- to adapter - VAS
5565- and to battery positive terminal in engine compartment.
Note
The following operation is to make the fuel pump run when the
engine is stopped.
– The quantity of fuel flow quantity delivered by the fuel pump is
dependent upon battery voltage. Therefore, you must also
connect the hand-held multimeter to the lines -1- and -5- of the
adapter - VAS 5565- .
– Also use auxiliary measuring set - V.A.G 1594C- for this pur‐
pose.
118 Rep. gr.20 - Fuel supply system
León 2013 ➤ , León ST 2013 ➤
Fuel supply system, petrol engines - Edition 02.2017
– Pull fuel line -1- out of sealing flange. Opening the quick-re‐
lease coupling ⇒ page 68 .
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
– Connect pressure tester - VAS 6550- with hose - VAS
6550/3-4- to fuel delivery unit -1-.
– Connect hose - VAS 6550/3-4- to shut-off tap -A-.
– Connect pressure regulating valve - VAS 6550/4- to connec‐
tion -B- of pressure tester - VAS 6550– Hold end of hose of pressure regulating valve - VAS 6550/4in measuring container.
– Make sure that the radiator shut-off tap -C- is connected to the
pressure gauge -1-.
– Shut-off valves -A- and -B- on pressure tester -1- are open.
– Operate the 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 -arrowusing adjuster wheel.
– From this point on do not change position of adjuster wheel
anymore.
– Drain measuring container.
– Press remote control for 60 seconds whilst measuring voltage
at fuel pump.
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– Compare delivered quantity of fuel with specification indicated
in chart.
Name of axis
Control unit
Minimum delivery rate
Voltage at fuel pump with en‐
gine not running and pump run‐
ning.
cm3
Volt
Readout example:
During the test a voltage of 10.5 volts is measured. This equates
to a minimum delivery rate of approx. 1,200 cm3 in 60 seconds.
If result matches specification:
– Check to ensure that there are no crushing points (kinks) or
blockages in the fuel pipes.
– Check fuel lines for leaks and damage.
If specification is not obtained:
– Remove fuel delivery unit ⇒ page 55 .
– Check filter strainer for soiling.
– Check that all hose connections are properly connected to fuel
delivery unit -1-.
– Check to ensure that there are no crushing points (kinks) or
blockages in the fuel pipes.
– Check fuel lines for leaks and damage.
If no fault is found:
– Renew the fuel delivery unit ⇒ page 55 .
8.1.9
Checking fuel delivery rate, vehicles with four-wheel drive
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Special tools and workshop
equipment required
♦ Wedge - 3409♦ Remote control for V. A . G.
1348 - V.A.G 1348/3A♦ Multimeter e.g. hand-held
multimeter - V.A.G 1526E♦ Test instrument adapter/
DSO (5-pin) - VAS 5565♦ Pressure gauge - VAS
6550♦ Vehicle diagnostic and
service information system
♦ Connecting wire - VAS
6550/3-3♦ Connecting wire - VAS
6550/3-4♦ Overpressure control valve
- VAS 6550/4♦ Measuring container, ca‐
pacity ≥ 3 litre
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♦ Auxiliary measuring set - V.A.G 1594C-
Carry out the following working steps:
Checking fuel delivery rate in engine compartment, quick test:
Note
The fuel deliver rate will initially be checked in the engine com‐
partment using the guided function “Checking fuel delivery rate,
quick test”. If the minimum delivery rate is not achieved, a second
measurement must be carried out on the flange of the fuel supply
unit.
– Connect the vehicle diagnosis and service information sys‐
tem .
– Start Guided Functions.
– Select function: Check fuel delivery rate; quick test.
– Follow instructions on vehicle diagnosis tester .
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If specification is not obtained:
– Open tank flap unit -2-.
– Clean area around fuel filler neck.
– Unscrew cap -1- for fuel filler neck.
– Check fuel delivery rate, repeat quick test ⇒ page 122 .
If result matches specification:
– Check fuel tank breather ⇒ page 75 .
If specification is not obtained:
– Check to ensure that there are no crushing points (kinks) or
blockages in the fuel pipes.
– Check fuel lines for leaks and damage.
If no fault is found:
Proceed as follows to check fuel delivery rate at fuel delivery unit:
Checking fuel delivery rate on fuel delivery unit:
Note
♦ Opening the quick-release coupling ⇒ page 68 .
♦ When malfunctions occur in the dynamic behaviour of the ve‐
hicle with a fuel tank filled to max. 1/4, the fuel supply quantity
must be tested at a fuel tank filling level of 1/4 or less.
•
Speedometer must be okay. ⇒ page 83
•
Fuel pressure OK ⇒ page 90 .
•
The battery voltage must be at least 11.5 V, if necessary con‐
nect a battery charger ⇒ Electrical system; Rep. gr. 27 ;
Battery; Charging battery .
•
Fuel pump control unit - J538- OK ⇒ Vehicle diagnostic tester.
– Observe the safety measures ⇒ page 1
– Observe rules for cleanliness ⇒ page 4 .
– Connect battery charger ⇒ Electrical system; Rep. gr. 27 ;
Battery; Charging battery .
– Remove rear seat bench ⇒ General body repairs, interior;
Rep. gr. 72 ; Rear seats; Removing and installing seat bench/
individual seats .
– Unclip cover -1- for flange at retaining tabs -arrows-, using re‐
moval wedge - 3409- .
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– Clip sealing grommet -1- downwards from cover -2-.
– Guide cover -2- along wiring harness -3- backwards.
– Push tab -2- up in -direction of arrow A-.
– To do this, reach in with your finger between the floor plate
and fuel tank.
– At the same time, carefully pull fuel pump control unit -1- on
its wiring harness -3- in direction of arrow -B- out of its holder.
– Guide fuel pump control unit - J538- out towards interior be‐
tween fuel tank and floor panel.
– Place fuel pump control unit - J538- (with connector still con‐
nected) to one side.
– Check that connector -1- is fitted securely by pulling connector
without pressing catch. Malfunctions may arise when the con‐
nector has not been inserted correctly.
– Release push-fit connector -1- and pull off.
– Check contacts on plug and on fuel delivery unit for damage.
– Connect remote control - V.A.G 1348/3A- for V.A.G 1348 to
contact -1- using adapter cable -V.A.G 1348/3-3- and test lead
from auxiliary measuring set - V.A.G 1594C- .
– Tape off second connector contact of the adapter cable -V.A.G
1348/3-3- with insulating tape -arrow- to prevent short circuit.
– Connect contact -2- to negative battery terminal -A- using a
test lead from auxiliary measuring set - V.A.G 1594C- .
– Connect remote control - V.A.G 1348/3A- to battery positive
terminal clamp -B-.
Note
The following operation is to make the fuel pump run when the
engine is stopped.
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– Pull fuel line -3- off flange. Opening the quick-release coupling
⇒ page 68 .
CAUTION
The fuel system is pressurised.
Risk of injury due to fuel which may spurt out.
– Use safety goggles.
– Wear protection gloves.
– Release pressure: place clean cloth around connection and
carefully open connection.
– The quantity of fuel flow quantity delivered by the fuel pump is
dependent upon battery voltage. Therefore, you must also
connect the multimeter to the battery.
– Connect multimeter with auxiliary measuring set - V.A.G
1594C- .
– Connect pressure tester - VAS 6550- with hose - VAS
6550/3-4- to fuel delivery unit -1-.
– Connect hose - VAS 6550/3-4- to shut-off tap -A-.
– Connect the pressure regulating valve - VAS 6550/4- to the
connection -B- of the pressure tester - VAS 6550- .
– Hold end of hose of pressure regulating valve - VAS 6550/4in measuring container.
– Make sure that the radiator shut-off tap -C- is connected to the
pressure gauge -1-.
– Shut-off valves -A- and -B- on pressure tester -1- are open.
– Operate the remote control - V.A.G 1348/3A- .
Note
The fuel system pressurisation pump - G6- will be actuated.
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– Set pressure of 4.0 bar on pressure regulating valve -arrowusing adjuster wheel.
– From this point on do not change position of adjuster wheel
anymore.
– Drain measuring container.
– Press remote control for 60 seconds whilst measuring voltage
at fuel pump.
– Compare delivered quantity of fuel with specification indicated
in chart.
Name of axis
Control unit
Minimum delivery rate
Voltage at fuel pump with en‐
gine not running and pump run‐
ning.
cm3
Volt
Readout example:
During the test a voltage of 10.5 volts is measured. This equates
to a minimum delivery rate of approx. 1,200 cm3 in 60 seconds.
If result matches specification:
– Check to ensure that there are no crushing points (kinks) or
blockages in the fuel pipes.
– Check fuel lines for leaks and damage.
If specification is not obtained:
– Check to ensure that there are no crushing points (kinks) or
blockages in the fuel pipes.
– Check fuel lines for leaks and damage.
If specification is not obtained:
– Remove fuel delivery unit ⇒ page 55 .
– Check filter strainer for soiling.
– Check that all hose connections are properly connected to fuel
delivery unit -1-.
– Check to ensure that there are no crushing points (kinks) or
blockages in the fuel pipes.
– Check fuel lines for leaks and damage.
If no fault is found:
– Renew the fuel delivery unit ⇒ page 55 .
8.2
Removing and installing fuel pump con‐
trol unit - J538-
Special tools and workshop equipment required
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♦ Wedge - 3409-
Procedure:
Removal:
– Move front seats all the way forwards.
– Switch off ignition.
– Remove rear seat bench ⇒ General body repairs, interior;
Rep. gr. 72 ; Rear seats; Removing and installing seat bench/
individual seats .
– Unclip cover -1- for flange at retaining tabs -arrows-, using re‐
moval wedge - 3409- .
– Clip sealing grommet -1- downwards from cover -2-.
– Guide cover -2- along wiring harness -3- backwards.
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– Press up tab -2- -arrow A-; to do so, reach between floor panel
and fuel tank with your finger.
– At the same time carefully pull the fuel pump control unit -1on its wiring harness -3- in -direction of arrow B- out of its
holder.
– Guide fuel pump control unit - J538- out towards interior be‐
tween fuel tank and floor panel.
– Unplug electrical connector and remove fuel pump control unit
- J538- .
Installation
Installation is in the reverse sequence of removal. The following
must be taken into account:
Location ⇒ “1.1 Assembly overview - fuel tank”, page 6
– Connect wiring harness to fuel pump control unit - J538- .
– Pull on the connections to check if they have been connected
correctly.
– Insert fuel pump control unit - J538- into mounting bracket on
fuel tank and push it in until it audibly engages.
– Pull fuel pump control unit - J538- back in the opposite direc‐
tion to check it is properly secured.
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8.3
Removing and installing suction-jet
pump
On vehicles with four-wheel drive the fuel tank is divided into a
left and a right chamber. A suction-jet pump -2- is used for deliv‐
ering fuel from the left fuel tank chamber to the baffle housing of
the fuel delivery unit -1- on the right.
Spray jet functioning
The suction-jet pump works under a simple physical principle: A
propulsion jet coming from the electric fuel pump is routed into
the suction-jet pump via a spray nozzle, by which it is accelerated.
The accelerated stream of fuel draws off the surrounding fuel and
delivers it to the baffle housing of the fuel delivery unit.
Faults caused by defective suction-jet pump
Note
♦ The engine can stop due to fuel starvation if the suction-jet
pump is defective.
♦ If the suction-jet pump is defective, the engine can stop due to
fuel starvation when the tank is still 1/4 full.
If the suction-jet pump fails, 15 litres of fuel may remain (approx‐
imately 1/4 of the fuel tank capacity) in the left part of the fuel tank,
that the fuel supply unit would not be able to aspirate.
In the case of dead vehicles due to lack of fuel, although the fuel
tank is filled up to approx. 1/4 of its capacity, proceed as follows:
– Check fuel pump with ⇒ Vehicle diagnostic tester.
If fuel pump is OK, but no fuel is delivered:
– Add approx. 5 litres fuel.
– Start engine.
If engine now starts:
– Suction-jet pump cannot be renewed separately; renew fuel
tank ⇒ page 11 .
8. Fuel pump
129