Fuel system repair (VW Tiguan 1)

Instructions: Fuel hoses may only be secured to the engine using spring clamps of the appropriate series.

Removal and installation the fuel supply module

Caution: Condition: The fuel tank must be filled no more than 1/2 full. This ensures that the fuel level is below the fuel delivery module flange.

Instructions. When replacing the fuel supply module, check the fuel tank for large contaminants and clean it if necessary. Empty the fuel tank using the fuel extraction device -VAS 5190-. Strictly observe the safety regulations. Observe the rules for maintaining cleanliness.

Remove the rear bench seat. Remove the cover from the fuel delivery module.

CAUTION: The fuel in the fuel system is under pressure!

Disconnect connector "1" and fuel line "2" from the right (in the direction of movement) flange.



Unlock the "arrow" connector on the fuel pump control unit "J538" using the "T10118" tool and disconnect the connector.





Unscrew the round nut using the fuel level sensor wrench "3087". Slightly lift the fuel supply module and remove the sealing ring from the fuel tank opening.



Unlock and disconnect the fuel lines on the "arrow" fuel delivery module and remove the fuel delivery module from the fuel tank.



The fuel pump is installed in the reverse order.

Instruction: Fuel lines must be properly secured "arrows" (the hoses match the fittings). Check the tightness of the nipple connectors by pulling them! When installing the fuel supply module, make sure not to bend the float lever of the fuel level sensor "G". Install the fuel supply module sealing ring into the hole in the fuel tank dry. Wet the sealing ring with fuel (only when installing a fuel delivery module). Observe the installation position of the fuel supply module flange: eyelet "1" faces the direction of travel. The fuel supply module flange can only be installed in this position.

Removal and installation of fuel level sensor G

Remove the fuel supply module. Bend the 80mm welding wire as shown. Dimension "a": = 10mm, dimension "b": 70mm.



Unlock and remove the wire connector for the fuel level sensor 2. Press the welding wire "1" in the direction of the arrow - into the recess under the sensor.



At the same time, push the fuel level sensor "2" in the direction of the arrow out of the guides.

Installation

Insert the fuel level sensor into the fuel supply module guides and press down until it locks into place. Connect the connectors and check that they are securely locked. Install the fuel supply module.

Removal and installation the fuel pump control unit "J538"

Instructions: The installation location of the fuel pump control unit "J538" is on the fuel tank.

Installation location of the fuel pump control unit "J538"

• 1 - Bracket for fuel pump control unit "J538"
• 2 - Fuel pump control unit "J538"
• 3 - Connector

Remove the right, in the direction of travel, cover from the fuel supply module. Disconnect connector "1".



Insert screwdriver "2" directly above the connector into the bracket recess. Move the screwdriver in the -direction of the arrow-.



Press the screwdriver down in the direction of the arrow and at the same time remove the control unit on the connector from the bracket. Remove the connector from the control unit.

Installation

Insert connector "3" into control unit "2". Push control unit "2" into bracket "1" until it snaps into place. Further installation is carried out in the reverse order.

Electronic fuel management system (e-Gas system) - accelerator pedal module

• 1 - Connector, black, 6-pin
• 2 - Accelerator pedal position sensor "G79" with accelerator pedal position sensor 2 "G185", not adjustable. The accelerator pedal position sensor transmits data on the desired engine power to the engine control unit, "A" grooves for the puller
• 3 - 10 Nm
• 4 - Cap

Removal and installation the accelerator pedal module

Remove the steering column cover "arrows".



Using a screwdriver, pry off and remove cover "3". Unscrew mounting bolt "2". Unlock connector "1" "arrow" and remove the accelerator pedal module.



Insert the "T10233" puller as far as it will go into the recesses provided for this purpose, as shown in the figure, and remove the accelerator pedal module.

Installation

Insert connector "1" into accelerator pedal module "4". Lock connector "arrow". Install accelerator pedal module onto mounting pins "5". Install pin "6" into floor hole. Secure accelerator pedal module with bolt "2" and install cap "3". Install steering column trim. Tightening torque: accelerator pedal module to body 10 Nm.

Activated Carbon Absorber System (CAWA, CAWB)

• 1 - Activated carbon absorber, installation location: in the rear right wheel arch
• 2 - Pressure reducing valve with connecting hose, to dismantle, take the pressure reducing valve by the retaining ring (gray) and pull it up, check the reliability of the fastening
• 3 - From the fuel tank
• 4 - Ventilation line to the electromagnetic valve 1 of the activated carbon absorber "N80", secured to the fuel tank with clamps, check the reliability of the fastening
• 5 - Ventilation line from the activated carbon absorber, check the reliability of the fastening
• 6 - Electromagnetic valve 1 of the activated carbon absorber "N8Q", when the ignition is off the valve is closed, when the engine is warmed up it is controlled by a simulated signal from the engine control unit
• 7 - Connecting hose to the intake manifold, check the reliability of the fastening
• 8 - 10 Nm