D4B804C91DD-Fuel Supply System - Natural Gas Engines

Service
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Fuel supply system - natural gas engines
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Engine ID BSX
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Edition 09.2016
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
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20 - Fuel supply system olkswage es n
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2016 Volkswagen AG, Wolfsburg D4B804C91DD

Caddy 2004 ➤ , Caddy 2011 ➤
Fuel supply system - natural gas engines - Edition 09.2016
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions when working on vehicles with a gas system . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety regulations for working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 3
1.4 Safety precautions when using testers and measuring instruments during a road test . . . . 3
2 Identification . . . . w . a. g.e.n .A.G.. V. o.lk.s.w.ag. e.n.A.G.d.oe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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2.1 Engine number/engine
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data . . . . . . . . . . . . n.o.t g.u.a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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General thinformation . . . . . . . . . . . . . . . . . . . . . . . n. te.e.o . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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3.1 au cleanliness for working on supplementary/auxiliary
Rulesssfor ra
c heater and fuel system . . . . 6
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4 Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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4.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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4.2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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4.3 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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4.4 Pipe/wire routing and attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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4.5 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
spec
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5 Checking gas system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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5.1 Checking gas system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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1 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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1.1 Overview of fitting locations - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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2 Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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2.1 Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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2.2 Assembly overview - protective covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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2.3 Assembly overview - fuel tank shut-off valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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2.4 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

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2.5 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

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2.6 Removing and installing fuel tank shut-off valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

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2.7 Releasing high pressure in fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
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2.8 Removing and installing filling connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
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2.9 Determining residual pressure in natural gas tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3 Fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3.1 Assembly overview - fuel delivery unit and fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . 102
3.2 Removing and installing fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . 103
3.3 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4 Plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
4.1 Separating plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
5 fuel filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5.1 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5.2 Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
6 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
6.1 Assembly overview - activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
6.2 Checking fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
7 Accelerator pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
7.1 Assembly overview - accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
7.2 Removing and installing accelerator module with accelerator position sender G79 / G185
........................................................................ 115
8 Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
8.1 Checking fuel system pressurisation pump G6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Contents i
Caddy 2004 ➤ , Caddy 2011 ➤
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ii Contents
Caddy 2004 ➤ , Caddy 2011 ➤
00 – Technical data
1 Safety information
(VRL009354; Edition 09.2016)
⇒ “1.1 Safety precautions when working on vehicles with a gas
system”, page 1
⇒ “1.2 Safety regulations for working on fuel supply”, page 3
⇒ “1.3 Safety measures when working on vehicles with a start/
stop system”, page 3 wage
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⇒ “1.4 Safety precautions when using testers d b and measuring in‐
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1.1 Safety precautions when working on ve‐
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hicles with a gas system
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• Observe the following before renewing a fuel tank shut-off
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valve or natural gas tank:
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• Instruct the customer to leave as little natural gas in the tank
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• This is to avoid unnecessary costs for the customer as well as
the pollution of the environment.
• The fuel tank can be run empty, provided that the vehicle is
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Release pressure in the system before working on the natural
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Release pressure in high-pressure line ⇒ page 75 .

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Before removing the fuel tank shut-off valve , empty the fuel
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tank ⇒ page 32 .
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DANGER!
• The mechanic may be the source for electrostatic dis‐

charge. Therefore, it is mandatory to wear protective cloth‐
ing.
• Before performing any work on the natural gas system,
always take the necessary measures to discharge any
existing static charge and to avoid electrostatic charging.
• Electrostatic discharge at the vehicle or removed natural
gas tanks is not possible.
Wear protective gloves containing cotton to avoid injuries and
static charging.
Wear Volkswagen safety shoes to avoid static charging.
Wear Volkswagen workwear which contains residual moisture
and thus also prevents electrostatic discharge.
1. Safety information 1
Caddy 2004 ➤ , Caddy 2011 ➤
DANGER!
Before evacuating natural gas tanks, make sure to comply with

the following rules in order to avoid hazards:
♦ Do not evacuate natural gas tanks in confined spaces.
♦ The emptying process must be carried out outdoors.
♦ Before evacuation, establish a safety zone of 10 m x 10 m.
♦ The safety zone must be permanently supervised during
the evacuation.
♦ There must be no open flame or source of ignition in the
safety zone.
♦ Ensure that there are no sources of ignition and no open
fires near the vehicle and the fuel tank.
♦ Danger of explosion!
♦ Do not touch tank shut-off valves during the evacuation:
danger of freezing injuries.
♦ When natural gas no longer escapes from fuel tank, de‐
termine the residual pressure in the natural gas tank
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• If evacuation of the natural
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• Do not perform anys further repair work.
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• Contact your importer for further procedure regarding the

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natural gas tanks that are still filled with fuel.

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

ment, pay attention to the following due to the cramped condi‐
tions:
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♦ Route high-pressure lines in their original positions.

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♦ Ensure lines have sufficient clearance to all moving or hot

components.
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♦ Never attempt to reshape high-pressure lines of natural

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Check natural gas supply system for leaks
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⇒ “5.1 Checking gas system for leaks”, page 10 .
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After repair work on the gas system, the gas system must al‐ cted agen
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ways be checked ⇒ “5 Checking gas system”, page 10 .
Note
Tighten the union nuts of the fuel lines only to specified torque,
otherwise the special connection will be damaged and the pres‐
sure line must be renewed.
2 Rep. gr.00 - Technical data

Caddy 2004 ➤ , Caddy 2011 ➤
1.2 Safety regulations for working on fuel supply

Risk of injury from highly-pressurised fuel.
The fuel system is pressurised. Injury from fuel spray possible.
Before opening the fuel system: AG. Volkswagen AG d
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– Wear safety goggles. d byV
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– Wear protective gloves.
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– To release pressure, wrap a clean cloth around the connection
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and carefully loosen the connection.
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Procedure for releasing fuel pressure in high-pressure section ⇒
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Danger of fire from escaping fuel
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When the battery is connected and the driver door opens, the door
contact switch activates the fuel pump. Escaping fuel can ignite
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and cause a fire.

– Disconnect voltage supply to fuel pump before opening the
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fuel system.
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Malfunction caused by air in the fuel supply system

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Upon repair work on the fuel tank or the fuel delivery unit, air will C py
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be drawn in by the metering pump and conveyed to the auxiliary rig ht
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– Fill fuel take-off pipe with fuel.
1.3 Safety measures when working on vehicles with a start/stop system

Risk of injury due to unexpected motor start
If the vehicle's start/stop system is activated, the engine can start
unexpectedly. A message in the dash panel insert indicates
whether the Start/Stop system is activated.
– Deactivate Start/Stop system by switching off the ignition.
1.4 Safety precautions when using testers and measuring instruments during
a road test
Risk of injury through insecure testing and measuring instruments
When the front passenger airbag is triggered in an accident, in‐
sufficiently secured testing and measuring instruments become
dangerous projectiles.
– Secure testing and measuring instruments on the rear seat.
1. Safety information 3
Caddy 2004 ➤ , Caddy 2011 ➤
or
– Have a second person operate the test and measuring equip‐
ment on the rear seat.
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Caddy 2004 ➤ , Caddy 2011 ➤
2 Identification
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2.1 Engine number/engine data
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Identification code BSX
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Emission standards EU 4 / EU 5
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Displacement l 2.0
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Power kW 80
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RON Petrol 95 unleaded
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Natural gas Up to 1401)
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1) In gas mode, the engine output and the torque depend on the
quality of the natural gas used. The methane content for L gas
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(low calorific gas: methane content 79.8 - 87.0 %) and H gas (high
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calorific gas: methane content 87.1 - 98.0 %) may vary in different

regions.
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2. Identification 5
Caddy 2004 ➤ , Caddy 2011 ➤
3 General information
⇒ “3.1 Rules for cleanliness for working on supplementary/auxil‐
iary heater and fuel system”, page 6 Volkswa
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When working on the fuel supply and injection system, pay careful
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♦ Place removed parts on a clean surface and cover them over.
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♦ If repair work cannot be performed immediately, cover new
parts which have been removed from their packing.
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♦ Install only clean parts; do not remove new parts from pack‐
aging until immediately before installing. Do not use parts that
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♦ When the system is open: Do not work with compressed air.
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♦ Do not move the vehicle.
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♦ Immediately seal open lines and unions with clean plugs, for
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example from engine bung set - VAS 6122- .

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♦ Protect disconnected electrical connections from dirt and wa‐

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♦ To extract E 85 fuel, use only fuel extractor - VAS 5190 A- . C py
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Caddy 2004 ➤ , Caddy 2011 ➤
4 Repair notes
⇒ “4.1 Rules for cleanliness”, page 7
⇒ “4.2 General information”, page 8
⇒ “4.3 Contact corrosion”, page 8
⇒ “4.4 Pipe/wire routing and attachment”, page 9
⇒ “4.5 General repair instructions”, page 9
4.1 Rules for cleanliness

⇒ “4.1.1 Rules for cleanliness when working on fuel supply sys‐
tem/injection system”, page 7
⇒ “4.1.2 Rules for cleanliness when working on natural gas supply
system”, page 7
4.1.1 Rules for cleanliness when working on

fuel supply system/injection system
When working on fuel supply and injection system, pay careful
attention to the following “rules” for cleanliness:
♦ Thoroughly clean all joints and surrounding areas before dis‐olkswage es n
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♦ Place removed parts on a clean surface and cover them
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aging until immediately before installing. Do not use any parts
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box).
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♦ If system is open, do not work with compressed air. Do not
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move the vehicle.
♦ Immediately seal open lines and unions with clean plugs, for
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example from engine bung set - VAS 6122- .
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♦ Protect disconnected electrical connections from dirt and wa‐

ter and only reconnect in dry condition.
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4.1.2 Rules for cleanliness when working on

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When working on the natural gas supply, pay careful attention to

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the following “rules” for cleanliness:

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♦ Thoroughly clean all joints and surrounding areas before dis‐

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mantling.
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♦ Place removed parts on a clean surface and cover them over.
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Use lint-free cloths only!
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aging until immediately before installing. Do not use parts that
have been kept unpackaged (for example in toolboxes).
♦ If system is open, do not work with compressed air. Do not
move the vehicle.
4. Repair notes 7
Caddy 2004 ➤ , Caddy 2011 ➤
4.2 General information

⇒ “4.2.1 General notes on ignition system”, page 8
⇒ “4.2.2 General notes on the injection system”, page 8
4.2.1 General notes on ignition system

♦ For trouble-free operation of electrical components, a voltage
of at least 11.5 V is necessary.
♦ After completing work, read event memory of engine control
unit.
♦ Delete all event entries which may have occurred during testswagen AG. Volkswagen AG does
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♦ The readiness code must be generated if the event tho
rismemory e or
has been cleared ⇒ Vehicle diagnostic tester. s au ac
s
ce
le
♦ If, after fault finding, repairs or component tests, the engine

un
pt
starts, runs for a short period and then stops, then the fault
an
d
itte
y li
may be that the immobilizer is blocking the engine control unit.
erm
ab
ility
ot p
♦ Fault rectification: adapting engine control unit ⇒ Vehicle di‐
wit
is n
agnostic tester.
h re
ole,
spec
4.2.2 General notes on the injection system
t to the co
♦ After completing work, read event memory of engine control
unit.
rrectne
♦ Delete event memory entries which may have been made
during tests and repairs.
ss
♦ The readiness code must be generated if the event memory
o
cial p
f
has been cleared ⇒ Vehicle diagnostic tester.
inform
mer
♦ If fuel system has been opened, it must be bled before engine
atio
is started.
om
n
c
i
or
n
♦ Fuel hoses in engine compartment must be secured only with
thi
te
sd
spring-type clips which conform to production standard. The
iva
o
r
use of crimp-type or screw-type clips is not permissible.

p
cum
r
fo
en
ng
♦ The battery must be disconnected only with ignition switched

t.
yi Co
op
off. If a coded radio is installed, ascertain code before discon‐
C py
ht. rig
necting battery. rig ht
py by
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by lksw
♦ For trouble-free operation of electrical components, a voltage
cted agen
Prote AG.
of at least 11.5 V is necessary.
♦ Do not use sealants containing silicone. Particles of silicone
drawn into the engine will not be burnt in the engine and dam‐
age the Lambda probe.
♦ If, after fault finding, repairs or component tests, the engine
starts, runs for a short period and then stops, then the fault
may be that the immobilizer is blocking the engine control unit.
In this case, the control unit must be adapted ⇒ Vehicle diag‐
nostic tester.
♦ Vehicles with an airbag are fitted with a crash fuel shut-off. It
reduces the danger of a fire in a crash as the fuel pump is
switched off via the fuel pump relay.
♦ When driver door is opened, fuel pump is activated for 2 sec‐
onds to generate pressure in fuel system. This improves the
quality of the start behaviour.
4.3 Contact corrosion

Contact corrosion can occur if non-approved fasteners are used
on the vehicle (bolts, nuts, washers etc.).

Caddy 2004 ➤ , Caddy 2011 ➤
For this reason, only connecting elements with a special surface

coating have been fitted.
In addition, rubber, plastic and adhesives are made of non-con‐
ductive materials.
If there is any doubt about the suitability of parts, a general rule
is to use new parts ⇒ Electronic Parts Catalogue (ETKA) .
Please note: wage
es n
lks ot g
Vo
♦ It is recommended ed
by to use genuine parts which are ua tested and
ran
compatible thor with aluminium.
is tee
or
au a
♦ The use of genuine VW accessories is recommended. c
ss
ce
le
un
pt
♦ Damage resulting from contact corrosion is not covered by the
an
d
itte
warranty.
y li
erm
ab
ility
4.4 Pipe/wire routing and attachment
ot p
wit
is n
h re
Risk of damage to lines
ole,
spec
Lines may become damaged by moving or hot components.
t to the co
– Route lines in their original positions.
– Make sure there is sufficient clearance between the lines and
rrectne
moving as well as hot components.
ss o
cial p
f inform
mer
♦ Mark fuel lines, vacuum lines, pipes/hoses for activated char‐

atio
m
coal filter system and electrical wiring etc. before removal so

o
n
c
they can be re-installed in the original positions and correctly

or
n thi
e
connected. If necessary, take a photo or make a sketch.

t
sd
iva
o
pr
cum
4.5 General repair instructions

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fo
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ng
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Before starting work on the fuel supply system, the following steps
C py
t. rig
must be performed:
gh ht
pyri by
Vo
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by
♦ Before starting work, the extraction hose of a switched-on ex‐ cted agen
Prote AG.
haust gas extraction system must be laid near to the assembly
opening of the fuel tank.
♦ The extraction hose is used to extract fuel fumes.
♦ If no exhaust gas extraction system is available, a radial fan
with a displacement greater than 15 m3/h can be used provid‐
ing that motor is not in air flow.
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
♦ Interrupt power supply to fuel system pressurisation pump -
G6- ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations.
♦ Drain fuel tank ⇒ page 32 .
4. Repair notes 9
Caddy 2004 ➤ , Caddy 2011 ➤
5 Checking gas system

n AG 10 . Volkswagen AG
⇒ “5.1 Checking gas system for leaks”,
ksw
agepage does
not
ol
yV gu
5.1 Checking gas system for leaks db ara
e nte
ris
tho eo
au ra
⇒ “5.1.1 Distinguishing
ss between pressure sections of natural gas c
supply system”, page 10
ce
le
un
pt
an
d
⇒ “5.1.2 Checking gas system for leaks”, page 10

itte
y li
rm
ab
pe
⇒ “5.1.3 Checking gas system for leaks after working on high-
ility
ot
pressure section”, page 12
wit
, is n
h re
⇒ “5.1.4 Checking gas system for leaks after working on the low-
hole
spec
pressure section”, page 12
es, in part or in w
t to the co
⇒ “5.1.5 Determining pressure in gas system”, page 14
⇒ “5.1.6 Determining operating mode of natural gas vehicles”,
rrectness of i
page 14
l purpos
⇒ “5.1.7 Activating and deactivating natural gas mode”,

page 14
nform
ercia
5.1.1 Distinguishing between pressure sec‐

m
tions of natural gas supply system
a
com
tion in
r
The pressure sections are defined by the components of the nat‐

te o
thi
ural gas system.
s
iva
do
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rp
cum
A distinction is made between:
fo
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High-pressure section. ht. Cop py
rig
rig ht
Low-pressure section. py by
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by lksw
cted agen
The scope of the necessary leakage test following repair work Prote AG.
depends on the pressure section that has been worked on
⇒ page 10 .
5.1.2 Checking gas system for leaks

– Determine pressure in natural gas system ⇒ page 14 .
Conditions for testing
• If the actual pressure is less than the required minimum pres‐
sure of approx. 5 bar, refuel the vehicle.
• The natural gas tanks must be filled up to maximum pressure.
• However, the minimum fill level is ≥ 160 bar (80%).
• In order to avoid uncontrolled escape of natural gas after re‐
fuelling and before leakage test, pull relay for gas shut-off
valves - J908- out of relay carrier.
Note
♦ The gas shut-off valves are closed electrically upon pulling out
the relay for gas shut-off valves - J908- . The gas system can
still be filled.
♦ This will deactivate the gas system and it prevents the leakage
of larger amounts of gas through any possible leaks after the
gas system has been filled.
– Drive to the petrol station in petrol mode.

Caddy 2004 ➤ , Caddy 2011 ➤
After refuelling
– Drive back to the workshop in petrol mode.
– Before driving the vehicle into the workshop, reactivate natural
gas mode by inserting the relay for gas shut-off valves - J908-
into the relay carrier.
Note
♦ The fuel tank shut-off valves - N361/N362/N363/N429- will be

activated for only two seconds after the ignition has been
switched on.
♦ A mechanical noise (»clicking« sound) can be heard.
♦ During actuation of the fuel tank shut-off valves - N361/N362/
N363/N429- , listen carefully for the sound of leaking gas in
the section which was repaired.
♦ If the valves for tank shut-off - N361/N362/N363/N429- are not
actuated, perform an adaption drive to activate the natural gas
system.
♦ To ensure successful results from the adaption drive, the en‐
gine must repeatedly be operated with partial load during the
drive.
♦ To check whether the natural gas system has been success‐
fully actuated, consult the fuel gauge of the natural gas system
⇒ page 14 .
• Before driving the vehicle into the workshop, listen carefully

for the sound of leaking gas.
If noise can be heard:
DANGER!
• Risk of explosion and danger to life due to ksescaping
wage nat‐ es n
ural gas. A hissing noise is a sign that Vol are leaks in
ythere
ot g
ua
d b ran
the natural gas system. Leaks inhnatural
or
ise gas system may tee
lead to uncontrolled escape of anatural
ut gas. or
ac
ss
Risk of explosion leading to loss of life or serious injuries.
ce
le
un
pt
an
d
♦ Do not perform any kind of work on the natural gas system

itte
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erm
if leaking gas can be heard.

ab
ility
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♦ If a gas leak can be heard, do not drive the vehicle into the
wit
is n
workshop.
h re
ole,
spec
♦ Park the vehicle outside and cordon off the area around
it.
t to the co
rrectne
– Activate petrol operating mode ⇒ Vehicle diagnostic tester,

Release pressure in natural gas high-pressure
line .
ss o
cial p
– Wait until no sound of escaping gas can be heard.

inform
mer
When escaping gas can no longer be heard:

atio
om
– Drive vehicle into workshop.

n
c
i
or
n thi
e
– Loosen all threaded connections loosened during repair work

t
sd
va
and tighten according to specifications.

i
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pr
cum
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fo
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ng
– Drive vehicle out of workshop.

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
11
cted agen
Prote AG.
5. Checking gas system
Caddy 2004 ➤ , Caddy 2011 ➤
– Deactivate petrol operating mode ⇒ Vehicle diagnostic tester,

Release pressure in natural gas high-pressure
line .
– Check if the sound of escaping gas can be heard.

If no noise can be heard: n AG. Volkswagen AG do
lkswage es n
– Drive vehicle into workshop. byV
o ot g
ua
d ran
ir se
– Perform leakage test after working on high-pressure
utho section tee
or
or perform leakage test after working on low-pressure
ss
a section ac
⇒ page 12 .
ce
le
un
pt
an
d
5.1.3 Checking gas system for leaks after itte
y li
rm
ab
working on high-pressure section
pe
ility
ot
wit
, is n
h re
hole
DANGER!
spec
es, in part or in w
t to the co
• Risk of explosion and danger to life due to escaping nat‐
ural gas. A hissing noise is a sign that there are leaks in
the natural gas system. Leaks in natural gas system may
rrectness of i
lead to uncontrolled escape of natural gas.
l purpos

♦ Check natural gas system for leaks.
nform
mercia
a
com
t
Test pressure: 160 to 200 bar
ion in
r
te o
• Checking for leaks
thi
s
iva
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cum
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• Leakage test should be performed at a system pressure not
en
ng
t.
exceeding 200 bar.
yi Co
Cop py
t. rig
• Not all filling systems are capable of pressurising the gas sys‐
gh ht
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tem up to the maximum pressure. cop Vo
by lksw
cted agen
Prote AG.
• Minimum pressure is 160 bar.
The vehicle must not be handed over to the customer without a
leakage test having been performed successfully.
5.1.4 Checking gas system for leaks after

working on the low-pressure section
Special tools and workshop equipment required
♦ Gas leak tester for natural gas vehicles - VAS 6227-
♦ Leak detector spray (commercially available)

Caddy 2004 ➤ , Caddy 2011 ➤
Note
AG. Volkswagen
♦ The test »Checking gas system for leakslksafter
wage working on low- does n
n AG
pressure section« is not a substitute db
yfor
V the »Leakage test
o ot g
ua
according to manufacturer’s specifications«
rise which must be ran
tee
ho
performed according to the maintenance schedule.
aut or
ac
ss
♦ Any work, including leakage tests, on the natural gas system
ce
e
nl
pt
must be performed only by specially trained personnel. du
an
itte
y li
♦ Check the gas system for leaks if gas components in the low-
erm
ab
ility
pressure section have been loosened or renewed.
ot p
wit
, is n
h re
Test requirements:
hole
spec
es, in part or in w
• Test pressure: approx. 5 bar in low-pressure section,
t to the co
160 … 200 bar at transition between low-pressure section and
high-pressure section.
rrectness of i
• When the system activates, it can be assumed that the re‐
quired minimum pressure of 5 bar is attained.
l purpos
• If the system is not activated, it is impossible to perform a re‐

liable test. Fill natural gas system.
nf
ercia
or
• All screwed connections tightened to specifications.
m
m
atio
m
If shut-off valves have been closed electrically or mechanically

o
n in
or c
beforehand:
thi
te
sd
iva
– Reinsert relay for gas shut-off valves - J908- .
o
r
rp
cu
o
m
f
– Open shut-off valves -N361/N362/N363/N429- .
en
ng
t.
yi Co
op py
– Reactivate natural gas system ⇒ page 14 . t. C rig
gh ht
pyri by
Vo
co lksw
by
cted
DANGER!
agen
Prote AG.

♦ Always make sure there are no possible sources of igni‐
tion close to the natural gas system.
• Heed the safety precautions ⇒ page 1 .
Note
♦ The gas leak detector can only be used to find out whether
there is any gas in the surrounding air.
♦ Any other result than a green LED for »OK« is not permitted
on the gas leak detector. If a yellow or red LED lights up, a
leak detection spray must be used to verify whether gas is
really escaping from the vehicle's natural gas system or not.
When leak detection spray is being used, it must be ensured
that no bubbles come out of the sprayed area within a testing
time of 3 minutes. Any leaks that occur must be repaired, and
the test must then be repeated.
5. Checking gas system 13

Caddy 2004 ➤ , Caddy 2011 ➤
Procedure
– Take system pressure reading using ⇒ Vehicle diagnostic
tester ⇒ page 14 .
– All connections and components which have been opened or
exchanged, must be checked with gas leak tester for natural
gas vehicles - VAS 6227- and leak detector spray.
– Guide the gas leak tester around the point to be tested (»repair
area«), and take measurements every 90° for at least 5 sec‐
onds.
– Spray the respective connection or component with leak de‐
tection spray and observe approx. 3 minutes. Ensure that
there are no bubbles.
• If the leakage test does not detect a concentration of natural
gas and consequently no gas leak, the vehicle can be taken
into operation.
• If the leakage test detects a gas leak, the cause of fault must
be determined and eliminated. The leakage test must then be
carried out again.
• The vehicle must not be handed over to the customer without
a leakage test having been performed successfully.
5.1.5 Determining pressure in gas system

AG. Volkswagen n AG do
wage es n
Special tools and workshop equipment requiredy Volks ot g
ua
b
ed ran
♦ Vehicle diagnostic tester thoris tee
or
au ac
Determining pressure in gas system ss
ce
le
un
pt
– Connect ⇒ Vehicle diagnostic tester.
an
d
itte
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rm
– Switch on ignition.
ab
pe
ility
ot
– Determine pressure in natural gas system using ⇒ Vehicle di‐

wit
, is n
agnostic tester.
h re
hole
• The further procedure depends on the determined system spec

es, in part or in w
pressure; allocation ⇒ page 10 .

t to the co
5.1.6 Determining operating mode of natural

rrectness of i
gas vehicles
l purpos
Natural gas operating mode indicator in dash panel insert

– Start vehicle, and ensure that natural gas mode is indicated in
nform
ercia
dash panel insert.

m
• The vehicle is in natural gas mode if:

com
tion in
r
te o
thi
s
iva
Note
do
r
rp
cum
fo
en
g
The natural gas mode is indicated by the symbol -1- in the left fuel
n
t.
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op
gauge. C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
5.1.7 Activating and deactivating natural gas

mode

Caddy 2004 ➤ , Caddy 2011 ➤
♦ Handwheel - T50026-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
♦ Vehicle diagnostic tester
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
The fuel tank must be run empty, provided that the vehicle is fully
h re
functional and fit for the road.
hole
spec
es, in part or in w
t to the co
Deactivating natural gas mode
rrectness of i
Note
l purpos
When the gauge for natural gas shows “Tank empty” ⇒ page 14
and the engine control unit has switched to petrol mode, there
nf
ercia
may still a pressure of about 12 bar in the high-pressure section
or
of the natural gas system.
m
m
atio
om
n in
c
– Activate »Petrol mode« ⇒ Vehicle diagnostic tester, Guided

or
thi
e
Functions , Releasing pressure in natural gas high-

t
sd
iva
o
r
pressure line .
rp
cu
o
m
f
en
ng
t.
yi Co
op
DANGER!
C py
t. rig
gh ht
pyri by
Vo
co
by lksw
cted agen
Prote
AG.

♦ Check natural gas system for leaks.
– Close fuel tank shut-off valves - N361/N362/N363/N429- using

handwheel - T50026- .
– Pull relay for gas shut-off valves - J908- out of relay carrier.
Activating natural gas mode
– Insert relay for gas shut-off valves - J908- into relay carrier.
– Open fuel tank shut-off valves - N361/N362/N363/N429- using
handwheel - T50026- .
– Proceed with function to activate natural gas system ⇒ Vehicle
diagnostic tester, Guided Functions , Releasing pressure
in natural gas high-pressure line .
5. Checking gas system 15

Caddy 2004 ➤ , Caddy 2011 ➤
Note
The scope of the leakage test depends on the pressure section

⇒ page 10 which has been worked on.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
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ce
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
20 – Fuel supply system

yV
olksw
agen
AG. Volkswagen AG d
oes
not
g b ua
ed ran
ris tee
1 Fuel system tho
or
au ac
ss
⇒ “1.1 Overview of fitting locations - fuel system”, page 17
ce
e
nl
pt
du
an
itte
1.1 Overview of fitting locations - fuel sys‐
y li
erm
ab
tem
ility
ot p
wit
, is n
h re
⇒ “1.1.1 Overview of fitting locations - fuel system, Caddy”, page
hole
17
spec
es, in part or in w
t to the co
⇒ “1.1.2 Overview of fitting locations - fuel system, Caddy Maxi”,
page 19
1.1.1 Overview of fitting locations - fuel system, Caddy
rrectness of i
l purpos
1 - Filling connection
nform
ercia
❑ For natural gas.

❑ Removing and installing
m
at
om
⇒ page 76
ion
c
in t
or
2 - Fuel tank 1
his
ate
do
riv

p
cum
or
❑ With non-return valve

f
en
ng
t.
yi Co
❑ With tank shut-off valve Cop py
t. rig
4 - N429- opyri
gh by
Vo
ht
❑ Removing and installing by c lksw

cted agen
⇒ page 47 Prote AG.
❑ Emptying ⇒ page 32
3 - Fuel tank 2
❑ With tank shut-off valve
3 - N363-
⇒ page 47
4 - Fuel tank 3
2 - N362-
⇒ page 47
5 - Fuel tank 4
1 - N361-
⇒ page 47
6 - Front fuel line bolted connection
❑ First tighten union nut hand-tight then turn 90° (1/4 turn) further, counterhold on union with a spanner for
this.
1. Fuel system 17
Caddy 2004 ➤ , Caddy 2011 ➤
Note
♦ On no account must the union

nut be tightened further than
specified, since otherwise the
special threaded connection will
be damaged and the pressure
line must be renewed.
♦ Check natural gas supply sys‐
tem for leaks
⇒ “5.1 Checking gas system for
leaks”, page 10 .
♦ Perform gas system test
⇒ “5 Checking gas system”,
page 10 .
7 - Gas pressure regulator

❑ To high-pressure valve for gas mode - N372-
❑ With tank pressure sensor - G400-
❑ Removing and installing ⇒ Fuel supply - petrol engines; Rep. gr. 20 ; Gas pressure regulator; Removing
and installing gas pressure regulator
8 - Gas rail
❑ With gas injection valve 1 - N366- ... gas injection valve 4 - N369-
❑ With gas rail sensor - G401- .
AG. Volkswagen AG d
agen oes
olksw not
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un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
18
agen
Prote AG.
Rep. gr.20 - Fuel supply system
Caddy 2004 ➤ , Caddy 2011 ➤
1.1.2 Overview of fitting locations - fuel system, Caddy Maxi
⇒ page 76
2 - Fuel tank 1
5 - N430- . Volkswagen AG
gen AG does
❑ Removing and installing Volkswa not
gu
⇒ page 47 ed by ara
nte
ris
❑ Emptying ⇒ page u32tho eo
r a ac
ss
3 - Fuel tank 2
ce
e
nl
pt
du
an
itte
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erm
ab
4 - N429-
ility
ot p
wit
, is n
h re
⇒ page 47
hole
spec
es, in part or in w
t to the co
4 - Fuel tank 3
rrectness of i
3 - N363-
l purpos

⇒ page 47 nform
ercia
m
at
om
5 - Fuel tank 4
on
c
in t
or

his
ate
do
riv

p
2 - N362-
um
for
en
ng
t.
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op
⇒ page 47
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
6 - Fuel tank 5
Prote AG.

❑ With tank shut-off valve 1 - N361-
❑ Removing and installing ⇒ page 47
7 - Front fuel line bolted connection
❑ To loosen, the right underbody panel must be removed.
❑ First tighten union nut hand-tight then turn 90° (1/4 turn) further, counterhold on union with a spanner for
this.
Note

1. Fuel system 19
Caddy 2004 ➤ , Caddy 2011 ➤

tem for leaks
leaks”, page 10 .
⇒ “5 Checking gas system”,
page 10 .

❑ To high-pressure valve for gas mode - N372-
❑ With tank pressure sensor G400
❑ With gas rail sensor - G401- .
❑ Removing and installing ⇒ Fuel supply - petrol engines; Rep. gr. 20 ; Gas pressure regulator; Removing
and installing gas pressure regulator
9 - Gas rail with gas injectors
❑ Gas injection valve 1 - N366-
❑ With gas rail sensor G401
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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aut ra
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
20 Rep. gr.20 - Fuel supply system

Caddy 2004 ➤ , Caddy 2011 ➤
2 Fuel tank
⇒ “2.1 Assembly overview - fuel tank”, page 21
⇒ “2.2 Assembly overview - protective covers”, page 28
⇒ “2.3 Assembly overview - fuel tank shut-off valve”, page 30
⇒ “2.4 Emptying fuel tank”, page 32
AG. Volkswagen
⇒ “2.5 Removing and installing
lksw
agen fuel tank”,AGpage
does 47
n
o ot g
yV u
⇒ “2.6 Removing
ris
ed b and installing fuel tank shut-off valve”,
ara
nt
page 63 utho ee
or
a ac
ss
⇒ “2.7 Releasing high pressure in fuel system”, page 75
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le
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⇒ “2.8 Removing and installing filling connection”, page 76
an
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⇒ “2.9 Determining residual pressure in natural gas tank”,
pe
ility
page 79
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2.1 Assembly overview - fuel tank
hole
spec
es, in part or in w
t to the co
1 - Fuel line
❑ To gas pressure regula‐
rrectness of i
tor
l purpos
⇒ page 54
❑ When loosening, coun‐
nform
ercia
terhold on union with a

suitable tool
m
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❑ Take care not to bend or

n in
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te o
deform any lines

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❑ Route fuel lines in their

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❑ Ensure that there is suf‐
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❑ Tighten by hand as far
as stop
❑ Specified torque
⇒ page 23
2 - Fuel tanks (qty. 4)
⇒ page 47
3 - Support
❑ For fuel tanks
4 - Securing straps
❑ For fuel tanks
5 - Securing nuts
❑ For securing straps
❑ M10
❑ 40 Nm
6 - Washers
7 - Support
❑ For fuel tanks
2. Fuel tank 21
Caddy 2004 ➤ , Caddy 2011 ➤
8 - Support
❑ For fuel tanks
9 - Sealing cap
❑ For filling connection.
11 - Fuel line
❑ From filling connection
❑ When loosening, counterhold on union with a suitable tool
❑ Take care not to bend or deform any lines
❑ Route fuel lines in their original positions
❑ Ensure that there is sufficient clearance to all moving or hot components
❑ Tighten by hand as far as stop
❑ Specified torque ⇒ page 23
12 - Fuel tank shut-off valve 4 - N429-
❑ Assembly overview ⇒ page 30
❑ Removing and installing solenoid ⇒ page 72
13 - Fuel line
AG. Volkswagen AG d
❑ Route fuel lines in their original positions agen oes
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❑ Tighten by hand as far as stop aut
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❑ Specified torque ⇒ page 23 s
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14 - Fuel line
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15 - Fuel tank shut-off valves 1-3 - N361, N362 and N363-

l purpos

nf
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or

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16 - Fuel line
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❑ Route fuel lines in their original positions C py
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rig ht
❑ Ensure that there is sufficient clearance to all moving or hot components py by
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Caddy 2004 ➤ , Caddy 2011 ➤
17 - Sealing ring
❑ Always renew after removing
Installing anti-abrasion foil for tank 1

♦ Dimension -a- = 803 mm
♦ Dimension -b- = 18 mm
Note
The film is to be cut in a circle of 35 mm diameter.
Specified torques for high-pressure lines of gas pressure regula‐

tor
Component Torque setting

olkswagen AG
Securing bolt of securing swagstrap
en AG. V does 15 Nm
olk not
Vehicles with mechanical
ed
byV gas pressure regulator gu – Tighten by hand as far as stop
ara
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nte Then, tighten to 5 Nm +60° (used lines)
eo
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ss ♦ Orc tighten to 5 Nm +90° (new lines)
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Counterhold with a spanner on union of high-pressure

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Vehicles with electronically controlled pressure regu‐ – Tighten by hand as far as stop
ility
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♦ Or tighten to 5 Nm +180° (new lines)

hole
spec
es, in part or in w

t to the co
line
Fuel lines – Tighten by hand as far as stop
♦ Then, tighten to 5 Nm +90° (used lines)
rrectness of i
♦ Or tighten to 5 Nm +180° (new lines)

l purpos

line
nf
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orm
m
1) On no account must the union nut be tightened further than specified, since otherwise the special threaded connection will be damaged
atio
m
and the pressure line must be renewed.

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Assembly overview - natural gas tank, Caddy Maxi

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2. Fuel tank 23
Caddy 2004 ➤ , Caddy 2011 ➤
1 - Fuel tanks (qty. 5)

⇒ page 47
2 - Support
❑ For fuel tanks
3 - Securing straps
❑ For fuel tanks
4 - Securing nuts
❑ For securing straps
❑ M10
❑ 40 Nm
5 - Locking plate
6 - Support
❑ For fuel tanks
7 - Support
❑ For fuel tanks
8 - Support
❑ For fuel tanks
9 - Fuel line
⇒ page 54
❑ When loosening, coun‐
terhold on union with a
suitable tool
❑ Take care not to bend or
deform any lines AG. Volkswagen AG d
agen oes
❑ Route fuel lines in their olksw not
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original positions d by ara
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or
❑ Ensure that there is suf‐ aut
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ficient clearance to all ss c
moving or hot components
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pt
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10 - Fuel line
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hole
spec

es, in part or in w
t to the co

rrectness of i

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nf
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12 - Sealing cap
iva
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❑ For filling connection

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13 - Fuel line
Co
Cop py
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❑ From filling connection
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Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
14 - Fuel tank shut-off valve 5 - N430-
15 - Fuel line
❑ Specified torque ⇒ page 23 agen
AG. Volkswagen AG d
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16 - Fuel tank shut-off valves 1-4 - N361,edN362,
by
V
N363 and N429- ua
ran
ir s
❑ Assembly overview ⇒ page 30 tho tee
or
au ac
❑ Removing and installing ⇒ page ss 63
ce
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pt
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17 - Fuel line
erm
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spec
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❑ Ensure that there is sufficient clearance to all moving or hot components t to the co
rrectness of i

l purpos
18 - Sealing ring
❑ Always renew after removing
nf
ercia

rm
m
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19 - Fuel line
o
n in
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❑ To gas pressure regulator

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Assembly overview - petrol tank
2. Fuel tank 25
Caddy 2004 ➤ , Caddy 2011 ➤
1 - Bearings
❑ For fuel tank
❑ Qty. 4 n AG. Volkswagen AG do
lkswage es n
2 - Activated charcoal filter byV
o ot g
ua
d ran
❑ Activated charcoal filter ir se tee
ho
system ⇒ page 113 aut or
ac
ss
3 - Breather line
ce
le
un
pt
an
d
❑ To activated charcoal fil‐
itte
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ter solenoid valve 1 -
rm
ab
pe
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❑ Checking breather
h re
⇒ page 113
hole
spec
❑ Connection diagram
es, in part or in w
t to the co
⇒ page 113
❑ To pull off, press release
button on connection
rrectness of i
❑ Disconnect plug-in con‐
l purpos
nectors ⇒ page 106

❑ Plug-in connectors must
engage »audibly« when
nform
ercia
joined
m
a
❑ Ensure plug-in connec‐
com
tion in
tor is secured properly
r
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by pulling it.
s
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r
4 - Fuel supply line

rp
cum
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❑ Do not kink
n
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❑ Connection diagram
C py
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⇒ page 113
ht
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Vo
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❑ To pull off, press release Prote
cted AG.
agen
❑ Disconnect plug-in con‐
nectors ⇒ page 106
❑ Plug-in connectors must
engage »audibly« when joined
❑ Ensure plug-in connector is secured properly by pulling it.
5 - Fuel filter holder
6 - Bolt
❑ 3 Nm
7 - Breather line
❑ From fuel tank
❑ Ensure firm seating
❑ Checking breather ⇒ page 113
8 - Sealing ring
❑ Renewing
❑ Install dry
9 - Locking ring
10 - Nut
❑ Qty. 8 M 6
❑ 10 Nm
11 - fuel filter.
❑ With pressure regulating valve.
❑ Installation position: arrow indicates direction of flow.

Caddy 2004 ➤ , Caddy 2011 ➤
❑ Removing and installing ⇒ page 110 AG. Volkswagen AG d
agen oes
12 - Fuel line olksw not
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ara
d
❑ Do not kink orise nte
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ss a button on connection ra
c
❑ Plug-in connectors must engage »audibly« when joined
ce
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❑ Disconnect plug-in connectors ⇒ page 106
pe
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13 - Filler neck
, is n
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❑ Petrol
hole
spec
es, in part or in w
14 - Earth connection
t to the co
❑ To eliminate electrostatic charge
rrectness of i
15 - Bolt
l purpos
❑ M 6, Qty. 2
❑ Renew after removal
nform
ercia
❑ 10 Nm
m
a
com
t
16 - Sealing cap
ion in
r
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17 - Securing clips
thi
s
iva
do
18 - Connection hose
r
rp
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❑ From filler neck to fuel tank
en
ng
t.
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19 - Sleeves
. C rig
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rig by
❑ Qty. 4 copy Vo
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20 - Bolt
AG.
❑ Qty. 4
❑ M8
❑ 20 Nm
21 - Fuel line
❑ Do not kink
❑ To pull off, press release button on connection
❑ Disconnect plug-in connectors ⇒ page 106
❑ Plug-in connectors must engage »audibly« when joined
22 - Fuel pump control unit - J538-
❑ not fitted with engine code BSX
23 - Fuel delivery unit
❑ With fuel gauge sender - G-
❑ Removing and installing fuel gauge sender - G- ⇒ page 105
❑ With fuel system pressurisation pump - G6- .
❑ Checking fuel system pressurisation pump - G6- ⇒ page 118 .
❑ Connections on fuel delivery unit ⇒ page 103
❑ Installation position ⇒ page 103
24 - Fuel tank
25 - Breather line
❑ Checking breather ⇒ page 113
2. Fuel tank 27
Caddy 2004 ➤ , Caddy 2011 ➤
2.2 Assembly overview - protective covers

⇒ “2.2.1 Assembly overview - protective covers”, page 28
⇒ “2.2.2 Assembly overview - protective covers, Caddy Maxi”,
page 29
2.2.1 Assembly overview - protective covers

-Arrow- points in direction of travel.
1 - Front protective cover

2 - Rear protective cover
❑ Must be removed first
when dismantling
3 - Securing bolts
❑ 10 Nm
4 - Securing nuts
❑ 10 Nm
5 - Securing bolts
❑ 10 Nm
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at
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ion
c
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or
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ate
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or Caddy 2004 ➤ , Caddy 2011 ➤
u
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Fuel supply system - anaturalc gas engines - Edition 09.2016
ce
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2.2.2 Assembly overview - protective covers, Caddy Maxi
an
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-Arrow- points in direction of travel.
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ole,
1 - Rear protective cover
spec
❑ Must be removed first
t to the co
when dismantling
2 - Front protective cover
rrectne
3 - Securing nut
❑ 10 Nm
ss o
cial p
f
4 - Securing bolt
inform
❑ 10 Nm
mer
atio
m
5 - Securing nut
o
n
c
i
or
n
❑ 10 Nm
thi
te
sd
va
6 - Securing bolt
i
o
pr
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❑ 10 Nm
en
ng
t.
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Cop py
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pyri by
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cted agen
Prote AG.
2. Fuel tank 29
Caddy 2004 ➤ , Caddy 2011 ➤
2.3 Assembly overview - fuel tank shut-off

valve
⇒ “2.3.1 Assembly overview – fuel tank shut-off valve 1 N361 ”,
page 30
⇒ “2.3.2 Assembly overview - fuel tank shut-off valve 2-5 N362,
N363, N429 and N430 ”, page 31
2.3.1 Assembly overview – fuel tank shut-off valve 1 - N361-
1 - Plug
❑ With seal
❑ Check for damage, and
renew if necessary
❑ 9 Nm
2 - Securing nut
❑ 12 Nm
3 - Sealing ring
❑ Part of plug
⇒ Item 1 (page 30)
❑ Renew after removal AG. Volkswagen AG d
agen oes
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4 - Solenoid ed b ara
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ris
❑ Removing and installing aut
ho eo
ra
⇒ page 72 ss c
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un
5 - Sealing ring
pt
an
d
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erm
ab
ility
❑ Ensure proper seating
ot p
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in groove
is n
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ole,
6 - Spring ring
spec
❑ For allocation refer to ⇒ t to the co

Electronic parts cata‐
logue (ETKA) .
rrectne
7 - Fuel tank shut-off valve 1 -

N361-
s

s o
⇒ page 63
cial p
f inform
❑ 130 Nm
mer
atio
8 - Connection
om
n
c
❑ For securing line to fuel

i
or
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tank shut-off valve 1 -

t
sd
va
N361-
i
o
pr
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fo
❑ Renew each time after loosened

en
ng
t.
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❑ Insert with locking fluid, locking fluid ⇒ ETKA Cop py
ht. rig
❑ 18 Nm + 2 Nm
rig ht
py by
co Vo
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cted
9 - Sealing ring
agen
Prote AG.

❑ Between fuel tank shut-off valve to tank and fuel tank.
❑ Lightly coat with engine oil or petroleum jelly when installing.
10 - Union nut

Caddy 2004 ➤ , Caddy 2011 ➤
wage
es n
olks ot g
❑ Ensure that there is sufficientd bclearance
yV to all moving or hot components
ua
ran
ir se
❑ Tighten by hand as far as th stop
o tee
or
au ac
❑ Specified torque ⇒ page
ss 23
ce
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nl
11 - Fuel line
pt
du
an
itte
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❑ When loosening, counterhold on union with a suitable tool erm
ab
ility
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hole
spec
es, in part or in w
t to the co
2.3.2 Assembly overview - fuel tank shut-off valve 2-5 - N362, N363, N429 and
rrectness of i
N430-
l purpos
1 - Plug
nf
ercia
❑ With seal
orm
m
atio
❑ Check for damage, and
om
renew if necessary
n in
or c
thi
❑ 9 Nm
te
sd
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cu
2 - Securing nut
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m
f
en
ng

t.
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op py
❑ 12 Nm t. C rig
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pyri by
3 - Sealing ring
co Vo
by lksw
cted agen
Prote
❑ Part of plug
AG.
⇒ Item 1 (page 31)

4 - Solenoid
⇒ page 72
5 - Sealing ring
❑ Ensure proper seating
in groove
6 - Spring ring
❑ For allocation refer to ⇒
Electronic parts cata‐
logue (ETKA) .
7 - Fuel tank shut-off valve 2 -
N362-
⇒ page 63
❑ 130 Nm
8 - Connection
❑ For securing line to fuel
tank shut-off valve 2 -
N362-
❑ Renew each time after loosened
❑ Insert with locking fluid, locking fluid ⇒ ETKA
❑ 18 Nm + 2 Nm
9 - Fuel line
2. Fuel tank 31
Caddy 2004 ➤ , Caddy 2011 ➤
gen AG
. Volkswagen AG
a does
lksw not
10 - Union nut by
Vo gu
ara
ed nte
❑ When loosening, counterhold on union with a suitable ho tool
ris
eo
ut ra
❑ Take care not to bend or deform any lines ss
a c
ce
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nl
pt
du
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erm
ab
ility
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, is n
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11 - Sealing ring hole
spec
es, in part or in w
t to the co
❑ Between fuel tank shut-off valve to tank and fuel tank.
❑ Lightly coat with engine oil or petroleum jelly when installing.
rrectness of i
l purpos
2.4 Emptying fuel tank
nform
ercia
⇒ “2.4.1 Emptying fuel tank (natural gas), securing solenoid with

securing nut”, page 32
m
at
om
ion
⇒ “2.4.2 Emptying fuel tank (natural gas), securing solenoid with
c
in t
or
securing clip”, page 39
his
ate
do
riv
⇒ “2.4.3 Emptying petrol tank with fuel pump intact”, page 44

p
cum
for
en
ng
⇒ “2.4.4 Emptying petrol tank with defective fuel pump”,

t.
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page 46
C py
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2.4.1 Emptying fuel tank (natural gas), secur‐
cop Vo
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Prote
ing solenoid with securing nut
AG.

♦ Magnetic release tool - T10349-
♦ Key - T10521-

Caddy 2004 ➤ , Caddy 2011 ➤
♦ Key - T10522-
AG. Volkswagen AG d
agen oes
olksw not
♦ Handwheel - T50026- d byV gu
ara
ise nte
or eo
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aut ra
ss c
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an
d
itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectne
ss o
cial p
f inform
mer
atio
om
n
c
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or
n thi
te
sd
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fo
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Cop py
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rig ht
py by
co Vo
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cted
♦ Adapter - V.A.G 1274B/12A-
agen
Prote AG.
2. Fuel tank 33
Caddy 2004 ➤ , Caddy 2011 ➤
1 - Holder - VAS 523 001/6-

2 - Adapter - VAS 523 001/2-
3 - Sealing ring
4 - Retaining chain
5 - Gas discharge pipe - VAS
523 001/1-
6 - Adapter - VAS 523 001/3-
AG. Volkswagen AG d
agen oes
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d by ara
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Procedure C py
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– Heed the safety precautions ⇒ page 1 .
p by
o Vo
by c lksw
cted agen
– Observe rules for cleanliness ⇒ page 7 .
Prote AG.
– Observe safety precautions when working on natural gas sys‐

tem ⇒ page 1 .
When the gauge for natural gas shows “tank empty” and the en‐
gine control unit has switched to petrol, there is still a pressure of
about 12 bar in tank.

Caddy 2004 ➤ , Caddy 2011 ➤
WARNING
The emptying process must be carried out outdoors.

Ensure that there are no sources of ignition and no open fires
near the vehicle and the fuel tank.
Danger of explosion!
The fuel tank must always be securely lashed to the engine
and gearbox jack .
This will prevent the fuel tank from falling.
If the fuel tank is not securely lashed to the engine and gearbox
jack, any work on the fuel tank is prohibited.
– Remove respective fuel tank ⇒ page 47 .

– Align adjustable supports of gearbox support - T40173- rela‐
tive to fuel tank, and secure them.
– In order to properly secure adjustable supports, pull lever -1-
downwards, and position it such that the fuel tank can be
properly secured.
– Fit fuel tank -1- to gearbox support - T40173- with tensioning

strap - T10523- as shown in illustration. AG. Volkswagen AG d
agen oes
ksw
– Secure fuel tank against falling using tensioning strapb-y V ol not
gu
T10523- . rised ara
nte
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– Make sure that fuel tank shut-off valve is flush with
aut rigid mount‐ ra
s c
ing. s
ce
le
un
– Turn fuel tank so that connection for fuel line on fuel tank shut- pt
an
d
itte
off valve points vertically downwards. y li

rm
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ility
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, is n
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hole
spec
es, in part or in w
– Ensure that the ratchets of the tensioning straps are offset, as

t to the co
shown in illustration.
– Securely lash fuel tank -1- to gearbox support - T40173- using
rrectness of i
the two tensioning straps - T10523- .

l purpos
– When lashing, do not damage surface of fuel tank.

– If necessary, protect surface with suitable workshop equip‐
nform
ercia
ment.
m
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com
tion in
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te o
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Prote AG.
2. Fuel tank 35
Caddy 2004 ➤ , Caddy 2011 ➤
– Secure bracket - VAS 523 001/6- on gearbox support -

T40173- as shown in illustration.
– Use one or two bolts for this purpose -arrows-.
– Insert gas discharge pipe - VAS 523 001/1- into guide

-arrow- of bracket - VAS 523 001/6- .
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es, in part or in w
t to the co
rrectness of i
l purpos
– Screw suitable adapter - VAS 523 001- -2- onto gas discharge
pipe -4-.
nform
ercia
– Ensure that seal -3- is seated correctly.

m
a
com
– Screw adapter -2- onto fuel tank shut-off valve -1-.

ion in
r
te o
– Adapter only needs to be screwed on hand-tight. Do not use

thi
s
iva
any tools for this purpose, e.g. pliers or similar.

do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– On valves with two line connections, seal second connection

that is still open using cap from adapter - V.A.G 1274B/12A-
-2-.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
thor Caddy e2004
or ➤ , Caddy 2011 ➤
u
ss a Fuel supply system - natural gas enginesac - Edition 09.2016
ce
e
nl
pt
du
– Unscrew plug -arrow- on fuel tank shut-off valve -1-.
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
– Unscrew nut -arrow- on fuel tank shut-off valve -1- and remove
orm
it.
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Pull solenoid -2- in -direction of arrow- off fuel tank shut-off

valve -1-.
2. Fuel tank 37
Caddy 2004 ➤ , Caddy 2011 ➤
– Fit magnetic release tool - T10349- on valve.
Note
♦ The magnetic release tool - T10349- must remain fitted onto

the valve during the entire emptying process.
♦ It prevents the valve from becoming jammed.
– Fit hand wheel - T50026- to manual shut-off mechanism

-arrow- on fuel tank shut-off valve .
WARNING
♦ Establish a safety zone around the fuel tank, which must

not be entered while the fuel tank is emptied. Leave the
safety zone after you have opened wtheagemanual
n AG. Volkshut-off
swagen AG
does
valve. yV
olks not
gu b ara
ed
♦ Inhaling natural gas canthlead
or
is to poisoning of the respira‐ nte
e
tory tract. sa
u or
ac
s
ce
♦ When no more natural gas escapes from the fuel tank,
le
un
pt
perform a counterpressure check ⇒ page 79 .
an
d
itte
y li
erm
ab
ility
ot p
Checking for leaks at connections:
wit
is n
h re
ole,
spec
– Carefully open fuel tank shut-off valve in -direction of arrow-
using hand wheel - T50026- until natural gas escapes.
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
– After 1 or 2 seconds, close fuel tank shut-off valve .

um
r
fo
en
ng
t.
– Check connections between gas discharge pipe -4- and fuel
yi Co
op py
tank shut-off valve -1- for leaks. t. C rig
gh ht
pyri by
– To do so, use gas leak detector - VAS 6227- and commercially
co Vo
by lksw
cted
available leak detection spray.
agen
Prote AG.
If leaks are found:

– Check seal -3- for damage, and renew it if necessary.
– Check connection between gas discharge pipe -4- and fuel
tank shut-off valve -1- for soiling, and tighten it if necessary.
– If the leak cannot be rectified, do not use the gas discharge
pipe.

Caddy 2004 ➤ , Caddy 2011 ➤
If no leaks could be found, or if a leak was found but rectified:

– Carefully open fuel tank shut-off valve in -direction of arrow-
using hand wheel - T50026- until natural gas escapes.
– Carefully open fuel tank shut-off valve as far as possible with‐
out triggering the »restrictor valve«.
– The fuel tank shut-off valve must not be opened completely.
Note
♦ Depending on the tank pressure, the fuel tank shut-off valve

can be opened completely.
♦ Fully opening will trigger the “restrictor valve”. Then only a
small amount of gas can escape.
If the valve has been opened too far, thus triggering the »restrictor
valve«:
– To reset the restrictor valve, the pressure must be equalised
by closing the »manual shut-off«.
– Close valve, then open it again making sure not to open it too
far this time.
– After approx. 2 minutes, the valve can be opened completely.
Continued for all:
– When natural gas no longer escapes from fuel tank, the man‐
ual shut-off valve must be closed again.
– Perform counterpressure check to ensure that the gas tank
has been sufficiently emptied ⇒ page 79 .
AG. Volkswagen AG d
agen oes
2.4.2 Emptying fuel tank (natural gas), secur‐
by
Volksw not
gu
ara
ing solenoid with securing clip
ed
ris nte
ho eo
aut ra
Special tools and workshop equipment required ss c
ce
le
un
pt

an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Fuel tank 39
Caddy 2004 ➤ , Caddy 2011 ➤
♦ Magnetic release tool - T10349-

1 - Holder - VAS 523 001/6-

2 - Adapter - VAS 523 001/2-
3 - Sealing ring
4 - Retaining chain
5 - Gas discharge pipe - VAS
523 001/1-
6 - Adapter - VAS 523 001/3-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi
Procedure
Co
Cop py
ht. rig
– Heed the safety precautions ⇒ page 1 .
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤

tem ⇒ page 1 .
When the gauge for natural gas shows “tank empty” and the en‐
gine control unit has switched to petrol, there is still a pressure of
about 12 bar in tank.
WARNING
The emptying process must be carried out outdoors.

Ensure that there are no sources of ignition and no open fires
near the vehicle and the fuel tank.
Danger of explosion!
The fuel tank must always be securely lashed to the engine
and gearbox jack .
This will prevent the fuel tank from falling.
If the fuel tank is not securely lashed to the engine and gearbox
jack, any work on the fuel tank is prohibited.

– Align adjustable supports of gearbox support - T40173- rela‐
tive to fuel tank, and secure them.
– In order to properly secure adjustable supports, pull lever -1-
downwards, and position it such that the fuel tank can be
properly secured. . Volkswage AG n AG d
agen oes
olksw not
yV gu
db ara
rise nte
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
– Fit fuel tank -1- to gearbox support - T40173- with tensioning

wit
, is n
strap - T10523- as shown in illustration.

h re
hole
spec
– Secure fuel tank against falling using tensioning strap -

es, in part or in w
T10523- .
t to the co
– Make sure that fuel tank shut-off valve is flush with rigid mount‐
ing.
rrectness of i
– Turn fuel tank so that connection for fuel line on fuel tank shut-
l purpos
off valve points vertically downwards.

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Fuel tank 41
Caddy 2004 ➤ , Caddy 2011 ➤

– Securely lash fuel tank -1- to gearbox support - T40173- using
the two tensioning straps - T10523- .
– When lashing, do not damage surface of fuel tank.
– If necessary, protect surface with suitable workshop equip‐
ment.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
– Secure bracket - VAS 523 001/6- on gearbox oris support -
e nte
T40173- as shown in illustration. aut
h eo
ra
ss c
– Use one or two bolts for this purpose -arrows-.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Insert gas discharge pipe - VAS 523 001/1- into guide
l purpos
-arrow- of bracket - VAS 523 001/6- .
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Screw suitable adapter - VAS 523 001- onto gas discharge

pipe -4-.
– Ensure that seal -3- is seated correctly.
– Screw adapter -2- onto fuel tank shut-off valve -1-.
– Adapter only needs to be screwed on hand-tight. Do not use
any tools for this purpose, e.g. pliers or similar.

Caddy 2004 ➤ , Caddy 2011 ➤

-2-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
– Release and pull off securing clip -1-.
ce
e
nl
pt
du
an
– Pull off solenoid -2- in direction of -arrow- and fit magnetic re‐
itte
y li
lease tool - T10349- in its place.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Actuate mechanical shut-off valve -2- on fuel tank shut-off
nf
ercia
valve using a suitable wrench (AF 6) or a hand wheel (if
orm
present).
m
atio
om
– Turning in anti-clockwise direction will open the shut-off valve.
n in
or c
thi
te
sd
iva
o
r
rp
cu
Note
o
m
f
en
ng
t.
yi Co
♦ The magnetic release tool - T10349- must remain fitted onto Cop py
ht. rig
the valve during the entire emptying process. rig ht
py by
co Vo
by lksw
♦ It prevents the valve from becoming jammed. Prote
cted AG.
agen
WARNING
♦ Establish a safety zone around the fuel tank, which must

not be entered while the fuel tank is emptied. Leave the
safety zone after you have opened the manual shut-off
valve.
♦ Inhaling natural gas can lead to poisoning of the respira‐
tory tract.
♦ When no more natural gas escapes from the fuel tank,
perform a counterpressure check ⇒ page 79 .
Checking for leaks at connections:

– Carefully open fuel tank shut-off valve until natural gas es‐
capes.
2. Fuel tank 43
Caddy 2004 ➤ , Caddy 2011 ➤
– After 1 or 2 seconds, close fuel tank shut-off valve .

– Check connections between gas discharge pipe -4- and fuel
tank shut-off valve -1- for leaks.
– To do so, use gas leak detector - VAS 6227- and commercially
available leak detection spray.
If leaks are found:
. Volkswagen AG
does gen AG
– Check seal -3- for Vdamage,
olks
wa and renew it if necessary.
not
y gu
db a
– Check connection
oris
e between gas discharge pipe -4- and ran
tefuel
tank shut-off
au valve -1- for soiling, and tighten it if necessary.
th eo
ra
ss c
– If the leak cannot be rectified, do not use the gas discharge
ce
e
nl
pt
pipe.
du
an
itte
y li
If no leaks could be found, or if a leak was found but rectified:
erm
ab
ility
ot p
– Carefully open fuel tank shut-off valve until natural gas es‐
wit
, is n
capes.
h re
hole
spec
– Carefully open fuel tank shut-off valve as far as possible with‐
es, in part or in w
out triggering the »restrictor valve«.
t to the co
– The fuel tank shut-off valve must not be opened completely.
rrectness of i
Note
l purpos
♦ Depending on the tank pressure, the fuel tank shut-off valve

nf
ercia
can be opened completely.

orm
m
atio
♦ Fully opening will trigger the “restrictor valve”. Then only a

om
small amount of gas can escape.

n in
or c
thi
te
sd
iva
If the valve has been opened too far, thus triggering the »restrictor
o
r
rp
cu
valve«:
o
m
f
en
ng
t.
yi Co
– To reset the restrictor valve, the pressure must be equalised Cop py
by closing the »manual shut-off«.
t. rig
gh ht
pyri by
Vo
co
– Close valve, then open it again making sure not to open it too
by lksw
cted agen
far this time.
Prote AG.
– After approx. 2 minutes, the valve can be opened completely.

Continued for all:
– When natural gas no longer escapes from fuel tank, the man‐
ual shut-off valve must be closed again.
– Perform counterpressure check to verify that the tank has
been successfully emptied ⇒ page 79 .
2.4.3 Emptying petrol tank with fuel pump in‐

tact

Caddy 2004 ➤ , Caddy 2011 ➤
♦ Vehicle diagnosis, testing and information system - VAS

5051B- or vehicle diagnosis, testing and information system -
VAS 5052-
♦ Fuel extraction unit - VAS 5190-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
♦ Adapter for fuel extraction - VAS 5190 /3 -
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
Procedure
f
en
ng
t.
yi Co
– Heed the safety precautions ⇒ page 1 . t. Cop py
rig
gh ht
– Observe rules for cleanliness ⇒ page 7 . yri
p by
o Vo
by c lksw
cted
– Pull off supply line -2-, and catch escaping fuel with a cloth
agen
Prote AG.
⇒ page 106 .
– Collect escaping fuel with a cleaning cloth.
WARNING
The fuel line is under pressure.

Fuel poses danger of injury to eyes and skin.
Wear protective goggles and protective clothing to avoid injury
and contact with the skin. Wrap a cloth around the connection
before loosening hose connections. Then reduce pressure by
carefully opening the connection.
2. Fuel tank 45
Caddy 2004 ➤ , Caddy 2011 ➤
– Connect fuel extractor - VAS 5190- with adapter for fuel ex‐
tractor - VAS 5190 /3- to fuel supply line.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
– Connect vehicle diagnostic tester.
hole
spec
es, in part or in w
t to the co
Note
The fuel pump is being activated when engine is not running. rrectness of i
l purpos
– Switch on ignition.
– Remove cap from fuel filler neck.
nf
ercia
or
– Perform function “Draining fuel system” in “Guided functions”.

m
m
atio
m
When the fuel tank is empty, »stop« the function to prevent the
o
n in
or c
fuel pump from running »dry«.

thi
te
sd
iva
– Operate shut-off tap on fuel extractor - VAS 5190- , until the

o
r
rp
cu
fuel tank is emptied.

o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
Note rig ht
py by
co Vo
by lksw
cted agen
Risk of damage to fuel system pressurisation pump - G6- when
Prote AG.
the fuel tank is empty. The fuel system pressurisation pump - G6-
must not run »dry«.
Bleeding fuel system

• Low-pressure side
• Fuel tank filled.
– Connect vehicle diagnostic tester.
– Perform the function “Bleeding fuel system” in “Guided func‐
tions”.
2.4.4 Emptying petrol tank with defective fuel

pump

Caddy 2004 ➤ , Caddy 2011 ➤
♦ Fuel extraction unit - VAS 5190-
Procedure
– Remove cone piece -2- from shaft -1- of fuel extractor -
VAS 5190- .
– At a distance of -a- = 1700 mm from end of extraction hose,
use insulating tape to mark -arrow- the hose of the fuel ex‐
tractor - VAS 5190- .
– Open fuel tank flap.
– Remove cap from fuel filler neck.
– Push the suction hose -arrow- of the fuel extractor - VAS 5190-
approx. 170…180 cm into the fuel filler neck and extract the
fuel. olks
wage es n
o
yV t gu
db ara
rise nte
tho eo
Note au ra
c
ss
ce
le
un
When no more fuel is extracted, the tank is emptied just enough

pt
an
d
for the sender flange to be opened without danger. The tank may
itte
y li
rm
be removed when containing a small amount of fuel

ab
pe
ility
⇒ page 60 .
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
2.5 Removing and installing fuel tank

⇒ “2.5.1 Removing and installing fuel tank, natural gas”,
rrectness of i
page 47
l purpos
⇒ “2.5.2 Removing and installing high-pressure lines”,

page 54
nform
ercia
⇒ “2.5.3 Removing and installing fuel tank, petrol”, page 60

m
⇒ “2.5.4 Removing and installing tank breather valves”,

a
com
tio
page 62
n in
r
te o
thi
2.5.1 Removing and installing fuel tank, natu‐

s
iva
do
r
ral gas
rp
cum
fo
en
ng
t.
yi Co
Special tools and workshop equipment required . Cop py
rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
2. Fuel tank 47
Caddy 2004 ➤ , Caddy 2011 ➤
♦ Engine and gearbox jack - V.A.G 1383 A-
♦ Gearbox support - T40173-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
♦ Tensioning strap - T10523-
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
♦ Torque wrench - V.A.G 1331-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
♦ 14 mm open-ring tool insert - V.A.G 1331/8-
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
♦ Engine bung set - VAS 6122-

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Commercially available paintbrush

♦ Wax ⇒ Electronic parts catalogue (ETKA)
Removing
Note
The fuel tanks can be removed or installed separately. The re‐

moval and installation is identical for both.
• The vehicle must be at room temperature (at least 14°C).

– Note safety precautions ⇒ page 1 .
tem ⇒ page 1 .
– Remove protective covers from underbody ⇒ page 28 .
2. Fuel tank 49
Caddy 2004 ➤ , Caddy 2011 ➤
WARNING

gas system.
– Release pressure in high-pressure line ⇒ page 75 .

– Ensure not to damage the painted surface when working on
the fuel tanks.
– If necessary, protect painted surface with suitable workshop
equipment.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and reconnecting battery.
– Measure distance to longitudinal member or to leaf spring on
left.
– To do this, measure distance between fuel tank shut-off valve
and longitudinal member or leaf spring. en AG. V
olkswagen AG
ag does
ksw not
– Make note of these measurements. y Vol gu
b ara
ed nte
ris
– Use this dimension when installing the new fuel thotank. eo
au ra
c
– Disconnect electrical connector -1- ss
on all solenoids -2- of fuel
ce
le
tank shut-off valves.

un
pt
an
d
itte
y li
– Close mechanical shut-off valves of all natural gas tanks.
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Version 1
nform
ercia
– Close shut-off valves -1- of all natural gas tanks by turning

handwheel - T50026- in -direction of arrow-.
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
Version 2
– Close shut-off valves -1- of all natural gas tanks in
-direction of arrow- using a commercially available socket
wrench (AF6) at bolt -2-.
Note
Due to limited space, the hand wheels for mechanical shut-off

valves have been discontinued.
– Carefully loosen threaded connections for high pressure lines

-1- and fuel tank shut-off valve -2- to allow residual gas to es‐
cape.
– When loosening high pressure lines, counterhold line connec‐
tions -arrows- with a suitable tool.

-1- and fuel tank shut-off valve -2- to allow residual gas to es‐
cape. G. Volkswage nA n AG d
wage oes
– When loosening high pressure lines, counterhold
Vol
ks line connec‐ not
gu
by
tions -arrows- with a suitable tool. ise
d ara
nte
r
tho eo
– Remove high-pressure lines froms aconnections.
u ra
c
s
ce
– Immediately seal open connections with suitable plugs from
le
un
pt
engine bung set - VAS 6122- .

an
d
itte
y li
erm
ab
– Place engine and gearbox jack - V.A.G 1383 A- with gearbox

ility
ot p
support - T40173- under fuel tank.

wit
is n
h re
ole,
spec
– Loosen securing straps -1-.

t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Fuel tank 51
Caddy 2004 ➤ , Caddy 2011 ➤
. Volkswagen AG
a gen AG d
– Secure fuel tank -1- to gearboxVol support - T40173- using ten‐
ksw
oes
not
gu
sioning straps - T10523-ed. by ara
n ris tee
utho or
a ac
ss
Note
ce
le
un
pt
an
d
itte
Disregard item -2-.
y li
erm
ab
ility
ot p
– Lower engine and gearbox jack - V.A.G 1383 A- slowly.
wit
is n
h re
ole,
spec
Note
t to the co
♦ If the securing strap is detached from fuel tank, the fuel tank
for petrol must be secured against being lowered.
rrectne
♦ Use bracket - T10351- for storing the fuel tanks if necessary.
ss o
Installing
cial p
f inform
Install in reverse order, noting the following:
mer
atio
om
n
c
i
or
n
Note
thi
te
sd
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o
pr
c
♦ There must not be any wax on the thread.
um
r
fo
en
ng
t.
yi
♦ No wax must be allowed to get into the fuel tank.
Co
Cop py
t. rig
gh
♦ No wax must be allowed to get into the lines.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Spray wax ⇒ Electronic parts catalogue (ETKA) into the cap
of spray bottle.
– Use a suitable, commercially available brush to apply the wax.
– Coat connection -arrows- between fuel tank -1- and fuel tank
shut-off valve -2- all-round with a thin layer of wax.

Caddy 2004 ➤ , Caddy 2011 ➤
– Tighten securing strap with plates to body.
Note
♦ Ensure correct installation position of plates.

♦ The bent edge must face towards outside and towards secur‐
ing strap.
– Slide mounting -arrow A- onto threaded pieces. The mounting

engages autonomously.
– Check inner sides of securing straps for soiling, and clean
them as required.
– Make sure that rubbers -B- are properly seated on securing
straps.
– Guide natural gas tank -1- into mounting -arrow- using engine
and gearbox jack - V.A.G 1383 A- .
lkswage es n
o ot g
byV ua
d ran
– Hook in locking device or of securing straps -arrows-.
ise
tee
th or
u
– Align fuel tank relative
ss
a
to longitudinal member or to leaf spring. ac
Use the noted measurements for this.
ce
le
un
pt
an
d
– Align fuel tank so that fuel lines can be connected free of

itte
y li
rm
stress.
ab
pe
ility
ot
– Turn and push fuel tank to align it so that union nut can be
wit
, is n
screwed on.
h re
hole
spec
– The lines must be installed free of stress.

es, in part or in w
t to the co
– Screw on line by hand as far as stop.

– Ensure that fuel line is properly seated in retainers.
rrectness of i
l purpos
WARNING
Take care not to bend or deform any fuel lines.

nform
ercia
The lines must be screwed on by hand as far as stop.

m
a
com
tio
The lines must be installed free of stress.

n in
r
te o
thi
Route fuel lines in their original positions.

s
iva
do
r
rp
cum
Ensure that there is sufficient clearance to all moving or hot

fo
en
g
components
n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Fuel tank 53
Caddy 2004 ➤ , Caddy 2011 ➤
– Tighten bolt -1- to specified torque.

– Check natural gas supply system for leaks
– Perform gas system test
⇒ “5 Checking gas system”, page 10 .
Torque settings
♦ ⇒ “2.1 Assembly overview - fuel tank”, page 21
♦ ⇒ “2.3 Assembly overview - fuel tank shut-off valve”,
page 30 gen AG
. Volkswagen AG
a does
lksw not
♦ ⇒ “2.2 Assembly overview - protective covers”,
db
yV
o
page 28 gu
ara
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ris
♦ ⇒ Electrical system; Rep. gr. 27 ; Battery;
tho Disconnecting and eo
connecting battery s au ra
c
s
ce
le
un
pt
an
d

itte
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erm
ab
Securing strap with plates to body 40 Nm
ility
ot p
wit
is n
h re
ole,
spec
2.5.2 Removing and installing high-pressure
t to the co
lines
rrectne
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c ce
le
un
pt
an
d
Overview
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Fuel tank 55
Caddy 2004 ➤ , Caddy 2011 ➤
1 - High-pressure filler connec‐

tion to natural gas tank 1
⇒ page 56
2 - Gas tank 1 high-pressure
line to gas tank 2
line to gas tank 3
line to gas tank 4
5 - Fuel tank 4 high-pressure
line to connecting piece
⇒ page 58
6 - Connector
❑ To loosen, the right un‐
derbody panel must be
removed.
AG. Volkswagen AG d
Torque setting agen oes
olksw not
y V gu
b ara
❑ New condition: first rise
d
nte
tighten union nut to 5 utho eo
ra
Nm then turn 180° (1/2 ss a c
turn) further, counter‐
ce
le
un
pt
hold line connection
an
d
itte
with a spanner to do
y li
rm
ab
this.
pe
ility
ot
❑ If refitting: first tighten
wit
, is n
union nut to 5 Nm then
h re
hole
turn 90° (1/4 turn) fur‐
spec
ther, counterhold line
es, in part or in w
t to the co
connection with a span‐
ner to do this.
rrectness of i
Note
l purpos

nform
ercia

m
a
com
tio

n in
r
te o
thi

s
iva
do
tem for leaks

r
rp
cum
fo

en
ng
t.
leaks”, page 10 .
yi Co
Cop py
t. rig
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yri by
⇒ “5 Checking gas system”, cop Vo
by lksw
page 10 .
cted agen
Prote AG.
7 - Connecting piece high-pressure line to gas pressure regulator ⇒ page 58

Removing high-pressure line from filler connection to natural gas

tank 1
– Remove protective covers on underbody:
• Caddy ⇒ page 28
• Caddy Maxi ⇒ page 29

Caddy 2004 ➤ , Caddy 2011 ➤
– Release and pull off electrical connectors -1- from tank shut-
off valve -2- of all fuel tanks (natural gas).
– Close mechanical shut-off valves on all fuel tanks (natural
gas).
Version 1
– Close shut-off valves on all fuel tanks (natural gas) using hand
wheel - T50026- .
– Close shut-off valve -1- by turning in clockwise direction
-arrow-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
or
Version 2 ss
au ac
ce
le
– Close shut-off valves -arrows- on all fuel tanks (natural gas)

un
pt
an
using commercially available spanner.

d
itte
y li
rm
ab
– Close shut-off valve -1- by turning in clockwise direction

pe
ility
-arrow-.
ot
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
♦ Due to limited space, the hand wheels for mechanical shut-off

rrectness of i
♦ Close the mechanical shut-off valves using a commercially

l purpos
available socket.
nform
ercia
WARNING
m
a
com
tion in

r
te o
gas system.
thi
s
iva
do
Connect ⇒ Vehicle diagnostic tester, and perform function “Re‐

r
rp
cum
fo
leasing pressure in natural gas high-pressure line”.

en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
– Note safety precautions ⇒ page 1 . p by
co Vo
by lksw
cted agen
– Observe rules for cleanliness ⇒ page 7 . Prote AG.

tem ⇒ page 1 .
– Remove rear left wheel housing liner ⇒ General body repairs,
exterior; Rep. gr. 66 ; Wheel housing liner; Removing and
installing rear wheel housing liner .
– Remove cap on filler neck connection and protect fuel filler
neck connections against dirt ingress.
2. Fuel tank 57
Caddy 2004 ➤ , Caddy 2011 ➤
– Remove bolts -arrow- and pull fuel filler neck out slightly down‐
wards. wage
es ks not
Vol gu
d by ara
e nte
ris
utho eo
ra
a c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Loosen union nut -arrow- of high-pressure line.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi
– Loosen union nut -1- on fuel tank shut-off valve -2-.
Co
Cop py
t. rig
gh ht
– When loosening high pressure lines, counterhold line connec‐ yri
p by
o Vo
tions -arrows- with a suitable tool.
c by lksw
cted agen
Prote AG.
– Remove high-pressure line -1-.
Installing
– Tighten union nut of fuel line using flared ring spanner tool
insert AF 14 - V.A.G 1331/8- without tension.
Torque settings
Removing high-pressure line from fuel tank 4 (or 5 on Caddy
Maxi) to gas pressure regulator

Caddy 2004 ➤ , Caddy 2011 ➤
– Release and pull off connectors -1- on fuel tank shut-off valve
of all natural gas tanks.
gas).
Version 1
wheel - T50026- .
lkswage es n
o ot g
byV ua
Version 2 o
ir se
d ran
tee
th or
– Close shut-off valves -arrows- au fuel tanks (natural gas)
onss all ac
using commercially available spanner.
ce
le
un
pt
an
d
itte
y li
rm
ab
Note
pe
ility
ot
wit
, is n
♦ Due to limited space, the hand wheels for mechanical shut-off
h re
hole

spec
es, in part or in w
♦ Close the mechanical shut-off valves using a commercially t to the co

available socket. rrectness of i
WARNING
l purpos

gas system.
nform
ercia
Connect ⇒ Vehicle diagnostic tester, and perform function “Re‐

m
a
com
leasing pressure in natural gas high-pressure line”.

ion in
r
te o
thi
s
iva
do

r
rp
cum
fo
en
g

n
t.
yi Co
Cop py
t. rig
gh ht
yri
tem ⇒ page 1 .
p by
co Vo
by lksw
cted agen
– Remove fuel tank 4 (Caddy) or fuel tank 5 (Caddy Maxi)
Prote AG.
⇒ page 47 .
2. Fuel tank 59
Caddy 2004 ➤ , Caddy 2011 ➤

-1- of fuel tank shut-off valve -2- to allow residual gas to es‐
cape.
– Remove high-pressure line.
– Remove right underbody cladding.
– Separate high pressure line at connection on underbody. AG. Volkswagen AG d
agen oes
olksw not
y V gu
– Unclip high-pressure line from retainers on underbody and d b ara
ise nte
separate fuel lines at plug-in connectors as necessary.thor eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Separate breather line -1- and fuel supply line -2-, depress
ility
ot p
release buttons for this.
wit
, is n
h re
hole
spec
– Unscrew union nut of high-pressure line on gas regulator.
es, in part or in w
t to the co
rrectness of i
– Pull out high-pressure line upwards together with heat shield.
l purpos
Installing
nform
ercia

m
at
om
io
n
c
in t
or
his
ate
do
priv
c
– Tighten union nut of fuel line using flared ring spanner tool
um
for
insert AF 14 - V.A.G 1331/8- without tension.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
WARNING yri
p by
co Vo
by lksw
cted agen
Prote
On fuel lines that are newly installed (initial installation), union
AG.
nuts should first be tightened hand-tight, then turned 180° fur‐

ther.
In case of repair, union nuts are also first tightened hand-tight,
then turned 90° further.

Torque settings
2.5.3 Removing and installing fuel tank, petrol


Caddy 2004 ➤ , Caddy 2011 ➤
♦ Engine and gearbox jack - V.A.G 1383 A-
AG. Volkswagen AG d
agen oes
olksw not
yV gu
Removing ed b ara
nte
ris
o eo
– Heed the safety precautions ⇒ page 1 . aut
h
ra
ss c
ce
e
nl
pt
du
an
– With ignition switched off, disconnect battery earth strap.
itte
y li
erm
ab
Emptying fuel tank with fuel pump intact ⇒ page 44 .
ility
ot p
wit
, is n
Emptying fuel tank when fuel pump is defective ⇒ page 46 .
h re
hole
spec
– Remove natural gas tank 3 and, if required, natural gas tank
es, in part or in w
2 ⇒ page 47 .
t to the co
WARNING
Fuel supply line is pressurised. Wear protective goggles and rrectness of i

l purpos
protective clothing to avoid injury and contact with the skin.

Wrap a cloth around the connection before loosening hose
nform
connections. Then release pressure by carefully pulling hose

ercia
off connection.
m
at
om
ion
c
in t
or
– Disconnect fuel supply line -1- and breather line -2- from un‐
his
ate
derbody. Separate plug-in connectors ⇒ page 106 .

do
priv
cum
or

f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
Note
py by
co Vo
by lksw
cted agen
Prote AG.
Press in circlip to release line ⇒ page 106 .
– Loosen securing clamps of connecting hose between fuel tank

and filler neck.
– Remove connecting hose from fuel tank.
2. Fuel tank 61
Caddy 2004 ➤ , Caddy 2011 ➤
– Support fuel tank -1- with engine and gearbox jack - V.A.G
1383 A- -2-.
– Loosen fuel tank securing bolts.
– Slowly lower engine and gearbox jack - V.A.G 1383 A- until 5-
pin connector can be pulled off the fuel delivery unit.
– Pull off 5-pin connector from fuel delivery unit flange.
– Disconnect breather lines from both breather valves on top of
fuel tank.
– Lower fuel tank further with engine and gearbox jack - V.A.G
1383 A- . AG. Volkswagen AG d
agen oes
lksw not
Installing by Vo gu
ara
d
ise nte
Install in reverse order, noting the following: uthor eo
a ra
s c
♦ Install breather lines and fuel lines free of kinks. s
ce
le
un
pt
♦ Do not interchange supply line and breather line (black supply
an
d
itte
y li
line, white breather line).
rm
ab
pe
ility
♦ Ensure that line connections are tight.
ot
wit
, is n
h re
♦ After installing fuel tank, check that the supply line and breath‐
hole
er lines are still clipped onto the fuel tank.
spec
es, in part or in w
t to the co
♦ Bleed fuel system ⇒ Rep. gr. 24 ; Injection system; Filling/
bleeding fuel system .
Torque settings
rrectness of i
♦ ⇒ page 21
l purpos
♦ ⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit
nform
ercia
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing

liner; Assembly overview – rear wheel housing liner
m
a
com
tion in
r
2.5.4 Removing and installing tank breather

te o
thi
s
iva
valves
do
r
rp
cum
fo
en
g

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

tem ⇒ page 1 .

Caddy 2004 ➤ , Caddy 2011 ➤
– Remove fuel tank ⇒ page 60 .

– Mark installation position of breather valve -1-.
– Remove breather hose from valve.
– Loosen nuts -2- of securing ring -3-.
– Remove breather valve -1- and seal -4- from opening in fuel
tank.
Installing
♦ Install breather lines and fuel lines free of kinks.
♦ Ensure that line connections are tight.
♦ After installing fuel tank, check that the supply, return and
breather lines are still clipped onto the fuel tank.
Torque settings
♦ ⇒ page 21
♦ ⇒ “3.1 Assembly overview - fuel delivery unit and fuel gauge
sender”, page 102
Nut for securing ring 10 Nm
AG. Volkswagen AG d
agen
2.6 Removingby
Vol
ksw and installing fuel
oes
notank
t gu shut-
off
ris valve
d ara
e nte
ho
t e or
au ac
⇒ “2.6.1 Versions
ss of fuel tank shut-off valve”, page 63
ce
le
un
⇒ “2.6.2 Removing and installing fuel tank shut-off valve, solenoid

pt
an
d
itte
valve with securing clip”, page 64

y li
erm
ab
⇒ “2.6.3 Removing and installing fuel tank shut-off valve, solenoid

ility
ot p
valve with securing nut”, page 68

wit
is n
h re
ole,
⇒ “2.6.4 Removing and installing solenoids of fuel tank shut-off

spec
valves N361/N362/N363/N429/N430 ”, page 72

t to the co
2.6.1 Versions of fuel tank shut-off valve

rrectne
Note
ss o
♦ Gradual introduction of modified tank shut-off valves. The dif‐

cial p
f in
ferences can be recognised in the following illustration, re‐

form
mer
garding securing the solenoid.

atio
m
♦ Therefore, the procedure for removing the tank shut-off valve

o
n
c
is different.
or
n thi
te
sd
iva
o
pr
Characteristics of tank shut-off valve

um
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Fuel tank 63
Caddy 2004 ➤ , Caddy 2011 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
1 = Removing tank shut-off valve, solenoid valves with securing

ss
clip ⇒ page 64 .
o
cial p
f inform
2 = Removing tank shut-off valve, solenoid valves with securing

mer
clip ⇒ page 68 .
atio
om
n
c
2.6.2 Removing and installing fuel tank shut-

i
or
n thi
te
off valve, solenoid valve with securing

sd
iva
o
pr
clip
um
r
fo
en
ng
t.
yi Co
Cop py
t. rig
WARNING
gh ht
pyri by
Vo
co lksw
by
cted agen
Tank shut-off valve must not be removed until respective tank Prote AG.
has been drained completely.

Caddy 2004 ➤ , Caddy 2011 ➤
Wrench - T10350-
Torque wrench - V.A.G 1332-

Removing
• Fuel tank must be at room temperature (at least 15 °C).
– Observe safety precautions ⇒ page 1 .
olksw
– Observe safety precautions when ageworking
n AG. V onanatural
gen AG
dogas
es n sys‐
ksw
tem ⇒ page 1 . by Vol ot g
u d ara
se nte
– Read system pressure
tho
ri using ⇒ Vehicle diagnostic tester. e or
u ac
sa
– Select Guided sFunctions .
ce
le
un
– Read Measured values for "Gas tank – interior pressure" in pt

an
d
itte
"Engine" option. y li
erm
ab
ility
ot p
– Ensure not to damage the painted surface when working on wit

is n
the fuel tanks.

h re
ole,
spec

equipment.
t to the co

rrectne
– Secure fuel tank -1- on engine and gearbox jack - V.A.G 1383
A- and bracket - T40173- -2- using tensioning straps -
T10523- , as shown in illustration.
ss o
cial p

inform
mer
atio
m
– Secure fuel tank -1- with both tensioning straps - T10523- .

o
n
c
i
or
– Drain fuel tank ⇒ page 32 .

thi
te
sd
iva
o
r
– Thoroughly clean area around fuel tank shut-off valve .

p
cum
r
fo
en
ng
– Perform back pressure test ⇒ page 79 .

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
– Mark the position of the valve relative to the fuel tank.
by lksw
cted agen
Prote AG.
2. Fuel tank 65
Caddy 2004 ➤ , Caddy 2011 ➤
– Carefully loosen fuel tank shut-off valve using special wrench

- T10350- -1-.
– Ensure proper seating of guide of special wrench - T10350- in
support.
Using special wrench - T10350- , loosen and unscrew fuel tank
shut-off valve as follows:
Caution
Always follow the procedure below when unscrewing the fuel

tank shut-off valve .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
b ara
Procedure for unscrewing fuel tank shut-off
rise
d
valve nte
tho eo
– Carefully loosen fuel tank shut-off
ss au
valve using special wrench ra
c
- T10350- .
ce
le
un
pt
an
d
itte
y li
rm
ab
Note
pe
ility
ot
wit
, is n
♦ The O-ring will slip out of the groove while doing so and will
h re
allow for any residual gas to escape.
hole
spec
es, in part or in w
♦ Depending on the residual pressure, a loud noise may be au‐
t to the co
dible when the O-ring is released from the sealing surface.
– Slowly unscrew fuel tank shut-off valve by up to a half turn, so
rrectness of i
that residual gas can escape.
l purpos
DANGER!
nform
ercia
As soon as you can hear residual gas escaping, do not un‐

m
a
com
t
screw the fuel tank shut-off valve any further.
ion in
r
te o
thi
s
iva
do
• Wait until no more gas can be heard to escape before con‐

r
rp
cum
fo
tinuing work:
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
Checking play on fuel tank shut-off valve :

– Carefully move fuel tank shut-off valve in
-directions of arrows-.
– The fuel tank shut-off valve must not be unscrewed any further
while doing so.
• There must be a slight play.
– Let more residual gas escape.
n AG. Volkswagen A age G do
ksw es n
y Vol ot g
ua
b
DANGER!
ris
ed ran
tee
tho
or
au ac
Wait until
ss no more gas escapes
before carefully unscrewing
the fuel tank shut-off valve further.
ce
le
un
pt
an
d
itte
y li
erm
ab
– Unscrew fuel tank shut-off valve further in 90° steps.
ility
ot p
wit
is n
– Unscrew fuel tank shut-off valve further by a maximum of 2
h re
ole,
turns.
spec
t to the co
DANGER!
If no gas has escaped and no play can be observed, after the
rrectne
fuel tank shut-off valve has been unscrewed by 2 turns, do not
unscrew the fuel tank shut-off valve any further.
ss o
cial p
f inform
If no residual gas has escaped:

mer
atio
m
– Tighten fuel tank shut-off valve to 130 Nm.

o
n
c
i
or
– Do not perform any further work on fuel tank or fuel tank shut-
thi
te
sd
a
off valve .
iv
o
pr
cum
r
fo
If the residual gas has escaped and play can be observed:

en
ng
t.
yi Co
op
– Unscrew fuel tank shut-off valve . C py
t. rig
gh ht
yri
p by
co Vo
by lksw
cted agen
Prote AG.
tem ⇒ page 1 .
– Remove any wax residue.
Installing
Install in reverse order of removal. Observe the following:
Note
♦ Lightly coat seal with engine oil or Vaseline.

2. Fuel tank 67
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
Caddy 2004 ➤ , Caddy orise 2011 ➤ nte
eo
h
Fuel supply system
s aut
- natural gas engines - Edition 09.2016 ra
c
s
ce
le
un
– Fit new seal -2- on fuel tank shut-off valve -1-.
pt
an
d
itte
y li
– Screw fuel tank shut-off valve -1- into fuel tank -3-.
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f i
– Tighten fuel tank shut-off valve to 130 Nm using special
nform
wrench - T10350- .
mer
atio
m
– Install fuel tank ⇒ page 47 .

o
n
c
i
or
n thi
te
sd
a

iv
o
pr
cum
r
fo
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Coat connection between fuel tank -1- and fuel tank shut-off
valve -2- with wax.
– For allocation of wax refer to ⇒ Electronic Parts Catalogue
(ETKA) .
– Spray wax into the cap of the spray bottle.
– Use a suitable, commercially available brush to apply the wax.
– Apply a thin coat of wax all around -arrows-.
Note

Torque settings
Tank shut-off valve on fuel tank 130 Nm
Pipe inserts on tank shut-off 20 Nm
valve
2.6.3 Removing and installing fuel tank shut-

off valve, solenoid valve with securing
nut

Caddy 2004 ➤ , Caddy 2011 ➤
♦ Key - T50025-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n
WARNING
thi
te
sd
iva
o
pr
c
Tank shut-off valve must not be removed until respective tank
um
r
fo
has been drained completely. en

ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
Removing
op Vo
by c lksw
cted agen
Prote AG.
• Fuel tank must be at room temperature (at least 15 °C).
tem ⇒ page 1 .
– Read system pressure using ⇒ Vehicle diagnostic tester.
– Select Guided Functions .
– Read Measured values for "Gas tank – interior pressure" in
"Engine" option.
– Ensure not to damage the painted surface when working on
the fuel tanks.
equipment.
2. Fuel tank 69
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
Caddy 2004 ➤ , Caddy 2011 ➤ ut
ho eo
ra
a
Fuel supply system - natural gas engines - Edition
ss 09.2016 c
ce
le
un
pt
– Secure fuel tank -1- on engine and gearbox jack - V.A.G 1383
an
d
itte
y li
A- and bracket - T40173- -2- using tensioning straps -
erm
ab
T10523- , as shown in illustration.
ility
ot p
wit
is n
h re
ole,
spec
– Secure fuel tank -1- with both tensioning straps - T10523- .
t to the co
– Thoroughly clean area around fuel tank shut-off valve .
rrectne
– Perform back pressure test ⇒ page 79 .
ss o
cial p
f inform
– Mark the position of the valve relative to the fuel tank.mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Carefully loosen fuel tank shut-off valve using special wrench

- T50025- .
Caution
Always follow the procedure below when unscrewing the fuel

tank shut-off valve .
Procedure for unscrewing fuel tank shut-off valve

– Carefully loosen fuel tank shut-off valve -1- using special
wrench - T50025- .
Note
♦ The O-ring will slip out of the groove while doing so and will
allow for any residual gas to escape.
♦ Depending on the residual pressure, a loud noise may be au‐
dible when the O-ring is released from the sealing surface.
– Slowly unscrew fuel tank shut-off valve by up to a half turn, so

that residual gas can escape.
DANGER!
As soon as you can hear residual gas escaping, do not un‐

screw the fuel tank shut-off valve any further.
• Wait until no more gas can be heard to escape before con‐

tinuing work:

Caddy 2004 ➤ , Caddy 2011 ➤
Checking play on fuel tank shut-off valve : lkswage es n
o ot g
byV ua
ed ran
– Carefully move fuel tank shut-off valve
oris in tee
-directions of arrows-. auth or
ac
ss
– The fuel tank shut-off valve must not be unscrewed any further
ce
le
un
pt
while doing so.
an
d
itte
y li
rm
• There must be a slight play.
ab
pe
ility
ot
– Let more residual gas escape.
wit
, is n
h re
hole
spec
DANGER!
es, in part or in w
t to the co
Wait until no more gas escapes before carefully unscrewing
the fuel tank shut-off valve further.
rrectness of i
l purpos
– Unscrew fuel tank shut-off valve further in 90° steps.

– Unscrew fuel tank shut-off valve further by a maximum of 2
nform
ercia
turns.
m
a
com
tion in
DANGER!
r
te o
thi
s
iva
do
If no gas has escaped and no play can be observed, after the
r
rp
cum
fuel tank shut-off valve has been unscrewed by 2 turns, do not
fo
en
g
unscrew the fuel tank shut-off valve any further.

n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
If no residual gas has escaped:
c by lksw
cted agen
Prote AG.
– Tighten fuel tank shut-off valve to 130 Nm.
– Do not perform any further work on fuel tank or fuel tank shut-
off valve .
If the residual gas has escaped and play can be observed:
– Unscrew fuel tank shut-off valve .
tem ⇒ page 1 .
– Remove any wax residue.
Installing
Note
♦ Lightly coat seal with engine oil or Vaseline.

2. Fuel tank 71
Caddy 2004 ➤ , Caddy 2011 ➤
– Fit new seal -2- on fuel tank shut-off valve -1-.

– Screw fuel tank shut-off valve -1- into fuel tank -3-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
– Tighten fuel tank shut-off valve to 130 Nm using special
erm
ab
wrench - T50025- .
ility
ot p
wit
, is n
– Install fuel tank ⇒ page 47 .
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Coat connection between fuel tank -1- and fuel tank shut-off
m
at
om
valve -2- with wax.

ion
c
in t
or
– For allocation of wax refer to ⇒ Electronic Parts Catalogue

his
ate
(ETKA) .
do
priv
cum
or
– Spray wax into the cap of the spray bottle.

f
en
ng
t.
yi Co
op
– Use a suitable, commercially available brush to apply the wax. C py
t. rig
gh ht
yri by
– Apply a thin coat of wax all around -arrows-. cop Vo
by lksw
cted agen
Prote AG.
Note

Torque settings
Tank shut-off valve on fuel tank 130 Nm
Pipe inserts on tank shut-off 20 Nm
valve
2.6.4 Removing and installing solenoids of

fuel tank shut-off valves -N361/N362/
N363/N429/N430-

Caddy 2004 ➤ , Caddy 2011 ➤
♦ Key - T10521-
♦ Key - T10522-
♦ Torque wrench - VAS 6854-

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Removing
– Remove protective covers from underbody ⇒ page 28 .
rrectness of i
– Disconnect connector -1- from respective solenoid.

l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Fuel tank 73
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
Caddy 2004 ➤ , Caddy 2011 ➤ autho eo
ra
Fuel supply system - natural gas engines - Edition 09.2016 ss c
ce
e
nl
pt
du
an
Solenoid with securing clip
itte
y li
erm
ab
– Release securing clip -1-.
ility
ot p
wit
, is n
– Remove solenoid -2-.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Solenoid with securing nut
m
at
om
i
– Unscrew plug -arrow- on fuel tank shut-off valve -1- using in‐
on
c
in t
sert tool AF 22 - T10522- .
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Unscrew nut -arrow- on fuel tank shut-off valve -1- using insert
tool AF 17 - T10521- and remove.
– Pull solenoid -2- in -direction of arrow- off fuel tank shut-off

valve -1-.
Installing
Solenoid with securing clip
– Make sure that securing clip is properly seated.
Solenoid with securing nut
– Tighten fuel tank shut-off valve using torque wrench - VAS
6854- and wrench - T10521/T10522- .
Torque settings
♦ ⇒ “2.2 Assembly overview - protective covers”, page 28
♦ ⇒ “2.3 Assembly overview - fuel tank shut-off valve”,
page 30

. VolkswageCaddy 2004 ➤ , Caddy 2011 ➤
Fuel supply gen AG - naturalngas
wasystem
AG do
engines
es n - Edition 09.2016
olks o
yV t gu
db ara
ir se nte
2.7 Releasing high pressure in fuel system aut
ho eo
ra
ss c
⇒ “2.7.1 Emptying fuel tank, solenoid secured with securing nut”,
ce
e
nl
page 75
pt
du
an
itte
y li
⇒ “2.7.2 Emptying fuel tank, solenoid secured with securing clip”,
erm
ab
page 75
ility
ot p
wit
, is n
2.7.1 Emptying fuel tank, solenoid secured
h re
hole
spec
with securing nut es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
♦ Vehicle diagnostic tester cop Vo
by lksw
cted agen
Prote
AG.

tem ⇒ page 1 .
– Remove underbody covers under fuel tanks ⇒ page 28 .
gas).
wheel - T50026- .
– Close shut-off valves by turning hand wheel in clockwise di‐
rection.
– Connect vehicle diagnostic tester .
– Use vehicle diagnostic tester to release pressure in high-pres‐
sure line ⇒ Vehicle diagnostic tester.
– Select option Release pressure in natural gas high-
pressure line in Guided functions .
– Follow instructions on vehicle diagnostic tester .
2.7.2 Emptying fuel tank, solenoid secured

with securing clip
tem ⇒ page 1 .
2. Fuel tank 75
Caddy 2004 ➤ , Caddy 2011 ➤
– Remove underbody covers under fuel tanks ⇒ page 28 .

Fuel tank shut-off valve without hand wheel:
– Close and open mechanical shut-off valve -2- on fuel tank
shut-off valve using a suitable wrench (SW 6).
Fuel tank shut-off valve with hand wheel:

– Close and open mechanical shut-off valve -2- on fuel tank
shut-off valve using hand wheel -arrow-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
or
– Close mechanical shut-off svalve
au -arrow- on all natural gas ac
tanks. s ce
le
un
pt
– Close shut-off valve -2- by turning in clockwise direction -1-.
an
d
itte
y li
rm
ab
– Connect vehicle diagnostic tester .
pe
ility
ot
wit
– Use vehicle diagnostic tester to release pressure in high-pres‐

, is n
h re
sure line ⇒ Vehicle diagnostic tester.

hole
spec
– Select option Release pressure in natural gas high-

es, in part or in w
t to the co
pressure line in Guided functions .
– Follow instructions on vehicle diagnostic tester .

rrectness of i
l purpos
2.8 Removing and installing filling connec‐

tion
nform
ercia

m
a
com
tion in

r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
♦ Engine bung set - VAS i6122-
se
d b ara
nte
or eo
th
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Removing
l purpos

nform
mercia

at
om
ion
c
– Remove high-pressure line from filler connection to fuel tank

in t
or
1 ⇒ page 54 .
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Fuel tank 77
Caddy 2004 ➤ , Caddy 2011 ➤
– Remove fuel tank flap unit ⇒ General body repairs, exterior;

Rep. gr. 55 ; Fuel tank flap unit .
– Unscrew securing nut -2- (left-hand thread) and remove wash‐
er -1-.
– Take filler connection out of bracket to rear.
– Immediately seal open lines with suitable plugs from engine
bung set - VAS 6122- .
Installing
– Carry out gas system test
⇒ “5 Checking gas system”, page 10
Torque settings

Securing nut for filling connection 35 Nm
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by Caddy
ara 2004 ➤ , Caddy 2011 ➤
ise nte
r
tho Fuel supply system - natural gas e oengines - Edition 09.2016
au ra
c
ss
ce
2.9 Determining residual pressure in natural
e
nl
pt
du
an
gas tank
itte
y li
erm
ab
ility
ot p
⇒ “2.9.1 Checking and converting adapter for counterpressure
wit
check on natural gas tank ”, page 79 , is n
h re
hole
⇒ “2.9.2 Self test of cooling system tester V.A.G 1274 B , solenoid
spec
es, in part or in w
secured with securing nut”, page 80
t to the co
⇒ “2.9.3 Self test of cooling system tester V.A.G 1274 B , solenoid
secured with securing clip”, page 85
rrectness of i
⇒ “2.9.4 Determining residual pressure in natural gas tank, sole‐
noid secured with securing nut”, page 90
l purpos
⇒ “2.9.5 Determining residual pressure in natural gas tank”, page

95
nf
ercia
orm
m
2.9.1 Checking and converting adapter for
atio
om
n in
counterpressure check on natural gas
or c
thi
e
tank
t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi
WARNING
Co
Cop py
t. rig
gh ht
yri
Before using the adapter for back pressure test on natural gas
p by
o Vo
by c lksw
tank , always check if it is the latest version. Prote
cted AG.
agen
Older versions of the adapter for counterpressure check on

natural gas tank must not be used unless converted accord‐
ingly.
The only adapter that may be used is the adapter - V.A.G
1274B/12 A- . All other adapters need to be converted accord‐
ingly.
Adapters with pressure relief valve need to be retrofitted
⇒ page 80 .
Distinguishing between different versions ⇒ page 79 .
Converting adapter for counterpressure check on natural gas
tank ⇒ page 80 .
Distinguishing between different versions:

A - Old version without pressure relief valve in connection piece
-2-
B - Adapter - V.A.G 1274B/12 A- new version with pressure relief
valve in connection piece -2-
The older version -A- of the adapter has no pressure relief valve
and has to be converted. Located after connection piece -1- is a
flexible hose.
The newer version -B- of the adapter is distinctly longer in area
-2-. This is the area where the pressure relief valve is located.
2. Fuel tank 79
Caddy 2004 ➤ , Caddy 2011 ➤
Adapter - V.A.G 1274B/12 A-1-

1 - Deflector cap
2 - Threaded union for fuel tank shut-off valve
3 - Connection piece
4 - Pressure relief valve
5 - Sealing ring
Use adapter - V.A.G 1274B/12 A-1- to convert from old to new
version.
Converting from old to new version:
tem ⇒ page 1 . . Volkswage
AG n AG d
agen oes
olksw not
V
– Carefully loosen and unscrew union nut d -2-.
by gu
ara
rise nte
– When doing so, counterhold on uniontho -2- with suitable tool. eo
s au ra
c
s
– Remove spacer ring from union -1-.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Insert filter strainer -2- into adapter -1-.
– Insert supplied seal -3- in adapter -1-. ss o
– Fit spacer ring -4- onto threaded piece of adapter -5-.
cial p
f inform
– Screw adapter - V.A.G 1274B/12 A-1- -1- onto adapter -5-, and
mer
tighten to 20 Nm.
atio
om
n
c
– Counterhold using a suitable tool while doing so.

i
or
n thi
te
sd
a
– Connect converted adapter for back pressure test on natural

iv
o
pr
gas tank to fuel tank shut-off valve.

um
r
fo
en
ng
t.
yi
– Carry out leakage test ⇒ page 80 .
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
2.9.2 Self test of cooling system tester - V.A.G
c by lksw
cted agen
Prote AG.
1274 B- , solenoid secured with securing
nut

Caddy 2004 ➤ , Caddy 2011 ➤
♦ Cooling system tester - V.A.G 1274 B-
AG. Volkswagen AG d
agen oes
ksw
♦ Handwheel by
V- T50026-
ol not
gu
d ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne

Adapter for counterpressure check on natural gas tank before
s
conversion:
s o
cial p
f inform
♦ Adapter for counterpressure check on natural gas tank (6 mm

mer
thread) - V.A.G 1274 B/12-

atio
om
n
c
♦ Adapter with pressure relief valve

i
or
n thi
te
sd
a
♦ Determine version of adapter for counterpressure check on

iv
o
pr
natural gas tank ⇒ page 79 .

um
r
fo
en
ng
t.
yi
♦ This adapter for counterpressure check on natural gas tank
Co
op py
(6 mm thread) - V.A.G 1274 B/12- needs to be converted
t. C rig
gh ht
⇒ page 79 . yri
p by
o Vo
by c lksw
cted
Adapter for counterpressure check on natural gas tank after con‐
agen
Prote AG.
version:
♦ Adapter for counterpressure check on natural gas tank - V.A.G

1274 B/12 A-
2. Fuel tank 81
Caddy 2004 ➤ , Caddy 2011 ➤

Note agen
AG. Volkswagen AG d
oes
olksw not
V gu
by
♦ The counterpressure
rised check must be performed after thearafuel
nte
tank has beenuthemptied.
o eo
ra
s a c
♦ The counterpressure check is used to verify that the pressure
s
ce
e
nl
in the fuel tank is below 1.0 bar.
pt
du
an
itte
y li
♦ If no counterpressure test has been performed, any work on
erm
ab
the fuel tank and the fuel tank shut-off valve is prohibited.
ility
ot p
wit
, is n
♦ Seal open connections using suitable plugs from engine bung
h re
set - VAS 6122- .
hole
spec
es, in part or in w
t to the co
Test precondition:
rrectness of i
l purpos

tem ⇒ page 1 .
nform
ercia
– Check adapter for counterpressure check on natural gas tank

and convert it accordingly if necessary.
m
at
om
ion
c

in t
or
his
ate
do
priv
cum
Note
for
en
ng
t.
yi Co
op
Prior to draining, check area around fuel tank shut-off valve for
C py
t. rig
gh
leaks ⇒ “5.1 Checking gas system for leaks”, page 10 .
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
WARNING
Never leave the fuel tank unattended when the tester is con‐
nected.
Note
♦ Different fuel tank shut-off valves may be installed.

♦ Depending on the version of the fuel tank shut-off valve in‐
stalled, 1 or 2 line connections may be present.
♦ In the case of fuel tank shut-off valves with 2 connections, each
of the connections must be sealed using the adapter for coun‐
terpressure check on natural gas tank and an additional seal‐
ing cap.
– Check adapter for counterpressure check on natural gas tank ,

and convert it to new version, if necessary ⇒ page 79 .

Caddy 2004 ➤ , Caddy 2011 ➤
– Close mechanical shut-off valve on tank shut-off valve on all

fuel tanks (natural gas) using handwheel - T50026- .
rection.
WARNING
To ensure that the counterpressure check is performed cor‐

rectly, always check the cooling system tester
. Volk-sV.A.G
wagen A1274
G do B-
gen AG
and the adapter for counterpressure
olkswacheck on natural gas tank
es n
ot g
(self test) beforehand. ed
byV ua
ra
is nte
or
If the self test fails, theauttools
h must not be used. eo
ra
ss c
ce
e
nl
pt
du
an
itte
y li
– Disconnect any adapter lines from cooling system tester -
erm
ab
V.A.G 1274 B- .
ility
ot p
wit
– Operate cooling system tester - V.A.G 1274 B- several times.
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Build up a pressure of 3.0 bar on cooling system tester - V.A.G

m
at
om
1274 B- .
ion
c
in t
or
– Observe pressure on pressure gauge of cooling system tester

his
ate
- V.A.G 1274 B- for 30 seconds.

do
priv
cum
or
If no pressure builds up or if the pressure drops again:

f
en
ng
t.
yi Co
op
Cooling system tester - V.A.G 1274 B- is not OK and must not be C py
t. rig
used for back pressure test. gh ht
pyri by
Vo
co lksw
by
If pressure builds up, and if the pressure does not drop: Prote
cted AG.
agen
The cooling system tester - V.A.G 1274 B- is OK and can be used

for back pressure test.
Check adapter for counterpressure check on natural gas tank as
described below.
2. Fuel tank 83
Caddy 2004 ➤ , Caddy 2011 ➤
Self-test on adapter for counterpressure check on natural gas

tank :
WARNING
Ensure that the magnetic release tool - T10349- is not placed

on the fuel tank shut-off valve -1-.
swage es n
Note byV
olk ot g
ua
d ran
ir se tee
o
On valves with two connections,
auth
the test must be performed on or
ac
both connections. ss
ce
e
nl
pt
du
an
– Check threads on fuel tank shut-off valve and on adapter for
itte
y li
erm
counterpressure check on natural gas tank for soiling, and
ab
ility
clean them if necessary.
ot p
wit
, is n
h re
– Connect adapter for counterpressure check on natural gas
hole
spec
tank -2- to cooling system tester - V.A.G 1274 B- -1-.
es, in part or in w
t to the co
– Open shut-off tap -arrow- on adapter for back pressure test on
natural gas tank .
rrectness of i
• Lever is then in line with direction of flow.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate

do
priv
tank -2- to fuel tank shut-off valve -1-.

um
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤

-2-.

1274 B- .
– Check connection between fuel tank shut-off valve and adapt‐
er for counterpressure check on natural gas tank , and tighten
it if necessary.
– Repeat self test ⇒ page 84 .
Adapter for back pressure test on natural gas tank is not OK and
must not be used for back pressure test.
If pressure builds up, and if the pressure does not drop:
Cooling system tester - V.A.G 1274 B- and adapter for counter‐
pressure check on natural gas tank can agbe
en Aused
G. Volfor counterpres‐
kswagen AG
does
sure check. olksw not
yV gu b ara
ed
– Press the pressure compensation
tho
ris button on the cooling sys‐ nte
e or
tem tester - V.A.G 1274
au B- . This will cause the pressure in the ac
ss - V.A.G 1274 B- and the adapter for
cooling system tester
ce
e
nl
counterpressure check on natural gas tank to be released.

pt
du
an
itte
y li
erm
ab
2.9.3 Self test of cooling system tester - V.A.G

ility
ot p
1274 B- , solenoid secured with securing

wit
, is n
h re
clip
hole
spec
es, in part or in w

t to the co

rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Fuel tank 85
Caddy 2004 ➤ , Caddy 2011 ➤

AG. Volkswagen AG d
agen oes
Adapter for counterpressure check on natural gas tank before olks
w not
yV gu
conversion: se
d b ara
nte
ri
ho eo
aut ra
♦ Adapter for counterpressure check on natural gas
ss tank (8 mm c
thread) - V.A.G 1274 B/13-
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
⇒ page 79 .
t to the co
version:
rrectness of i
l purpos

1274 B/13 A-
nf
ercia
or
m
m
atio
om
n in
or c
thi
Note
te
sd
iva
o
r
rp
cu
♦ The counterpressure check must be performed after the fuel

o
m
f
en
ng
tank has been emptied.

t.
yi Co
Cop py
.
ht rig
rig ht
py by
in the fuel tank is below 1.0 bar. co Vo
by lksw
cted agen
Prote
AG.
set - VAS 6122- .
Test precondition:
tem ⇒ page 1 .
– Check adapter for counterpressure check on natural gas tank
and convert it accordingly if necessary.

Caddy 2004 ➤ , Caddy 2011 ➤
Note
WARNING
nected.
Note

♦ In the case of fuel tank shut-off valves with 2 connections,
olks
wageeach es n
ot g
of the connections must be sealed using the adapter
d by V for coun‐ ua
ran
terpressure check on natural gas tank andoan ris additional seal‐
e
tee
ing cap. auth or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Close mechanical shut-off valve -2- on fuel tank shut-off valve
ility
ot p
using a suitable wrench (SW 6).
wit
, is n
h re
hole
spec
rection.
es, in part or in w
t to the co
WARNING
rrectness of i
rectly, always check the cooling system tester - V.A.G 1274 B-
l purpos
and the adapter for counterpressure check on natural gas tank

(self test) beforehand. nform
ercia
If the self test fails, the tools must not be used.

m
at
om
ion
c
in t
or
his
te
– Disconnect any adapter lines from cooling system tester -

a
do
riv
V.A.G 1274 B- .
p
cum
for
en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Fuel tank 87
Caddy 2004 ➤ , Caddy 2011 ➤

1274 B- .
The cooling system tester - V.A.G 1274 B- is not OK and must not
be used for back pressure test.
The cooling system tester - V.A.G 1274 B- is OK and can be used
for back pressure test.
AG. Volkswagen
Check adapter for counterpressure check on natural
lksw
agengas tank as AG does
not
described below. db
yV
o gu
a
e ran
ris tee
tho or
Self-test on adapter for counterpressure
au check on natural gas ac
ss
tank :
ce
le
un
pt
an
d
itte
y li
WARNING
erm
ab
ility
ot p
wit
is n
h re
on the fuel tank shut-off valve -1-.
ole,
spec
t to the co
Note
rrectne
On valves with two connections, the test must be performed on
both connections.
ss o
cial p
f in
– Check threads on fuel tank shut-off valve and on adapter for
form
mer
counterpressure check on natural gas tank for soiling, and

clean them if necessary. atio
om
n
c
i
or
n thi
e

t
sd
va
tank -2- to cooling system tester - V.A.G 1274 B- -1-.

i
o
pr
cum
r
fo
en
– Open shut-off tap -arrow- on adapter for back pressure test on

ng
t.
yi Co
natural gas tank . t. Cop py
rig
gh ht
yri
• Lever is then in line with direction of flow. p by
o Vo
by c lksw
cted agen
Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤

tank -2- to fuel tank shut-off valve -1-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
-2-.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op
– Build up a pressure of 3.0 bar on cooling system tester - V.A.G C py
t. rig
1274 B- .
gh ht
pyri by
Vo
o
by c lksw
– Observe pressure on pressure gauge of cooling system tester cted agen
Prote AG.
it if necessary.
Adapter for back pressure test on natural gas tank is not OK and
must not be used for back pressure test.
Cooling system tester - V.A.G 1274 B- and adapter for counter‐
pressure check on natural gas tank can be used for counterpres‐
sure check.
– Press the pressure compensation button on the cooling sys‐
tem tester - V.A.G 1274 B- . This will cause the pressure in the
cooling system tester - V.A.G 1274 B- and the adapter for
counterpressure check on natural gas tank to be released.
2. Fuel tank 89
Caddy 2004 ➤ , Caddy 2011 ➤
2.9.4 Determining residual pressure in natural

gas tank, solenoid secured with secur‐
ing nut
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

conversion:

thread) - V.A.G 1274 B/12-
⇒ page 79 .

Caddy 2004 ➤ , Caddy 2011 ➤

version:

1274 B/12 A-
Note

set - VAS 6122- .
♦ The only adapter that may be used is the adapterswfor
agecounter‐
es
pressure check on natural gas tank - V.A.Gb1274
yV
olk B/12 A- . not
gu
Older versions must be converted accordingly.
ris
ed ara
nte
ho eo
aut ra
Test precondition: ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
tem ⇒ page 1 .
h re
ole,
spec
t to the co
Note
rrectne
ss o
cial p
f in

form
mer

atio
om

n
c
i
or
n thi
e
– Perform self test of cooling system tester - V.A.G 1274 B-

t
sd
va
⇒ page 80 .
i
o
pr
cum
r
fo
en
ng
t.
yi Co
WARNING t. Cop py
rig
gh ht
yri by
cop Vo
by lksw
cted
nected.
agen
Prote AG.

(self test) beforehand.
2. Fuel tank 91
Caddy 2004 ➤ , Caddy 2011 ➤
Note

♦ In the case of fuel tank shut-off valves with 2 connections, each
ing cap.
– Close mechanical shut-off valve on fuel tank shut-off valve

-1- using hand wheel - T50026- .
rection.
AG. Volkswagen AG d
agen oes
olksw not
V gu
by ara
Performing counterpressure check: rised
nte
ho eo
aut ra
ss c
WARNING
ce
e
nl
pt
du
an
itte
y li
erm
ab
on the fuel tank shut-off valve .
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Connect adapter for back pressure test on natural gas tank to

cooling system tester - V.A.G 1274 B- -2- on fuel tank shut-off
l purpos
valve -1-.
nform
– In the case of fuel tank shut-off valves with 2 connections, each

ercia

m
at

om
io
ing cap.
n
c
in t
or
his
e
– Use hand wheel - T50026- -3- to carefully open mechanical

at
do
riv
shut-off valve on fuel tank shut-off valve -1-.

p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
– Close shut-off tap -arrow- on adapter for counterpressure

check on natural gas tank -2-. Lever is then at right angle to
direction of flow.

1274 B- .
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Fuel tank 93
Caddy 2004 ➤ , Caddy 2011 ➤
– Open shut-off tap -arrow- on adapter for counterpressure

check on natural gas tank -2-.
If pressure does not drop below 1.0 bar immediately:
The pressure in the fuel tank is too high because the fuel tank has
not been emptied completely.
WARNING
If the pressure does not drop due to excessive pressure in the

fuel tank, the fuel tank must be emptied again and the coun‐
terpressure check must be repeated before continuing work on
the system.
– Empty fuel tank again ⇒ page 32 .

– Repeat fuel pressure test ⇒ page 92 . . Volkswagen AG d
gen AG wa oes
olks not
If pressure still does not dropdbelow
by
V 1.0 bar: gu
ara
e nte
ris
– Empty fuel tank again
ut ⇒ page 32 .
ho eo
ra
sa c
– Repeat fuel pressure
s
test ⇒ page 92 . ce
le
un
pt
If pressure still does not drop below 1.0 bar:
an
d
itte
y li
erm
ab
Do not continue work on fuel tank.
ility
ot p
wit
If pressure drops very slowly:

is n
h re
ole,

spec

t to the co
it if necessary.
– Check connection between sealing cap of adapter for back
pressure check on natural gas tank (6 mm thread) - V.A.G
rrectne
1274 B/12- and fuel tank shut-off valve , and tighten it if nec‐
essary.
ss o

cial p
f inform
– Repeat fuel pressure test ⇒ page 92 .

mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
If pressure drops below 1.0 bar immediately:

– Repeat counterpressure check to verify that the previous
counterpressure check has been performed correctly
⇒ page 92 .
Note
♦ Upon completion of the counterpressure check, operate the

cooling system tester - V.A.G 1274 B- several times.
♦ No pressure must build up while doing so.
♦ Air can be heard to flow into the fuel tank.
♦ If pressure builds up, repeat the back pressure test
⇒ page 92 .
The fuel tank has been emptied sufficiently, and the pressure has
been released.
The fuel tank shut-off valve
agen
Acan
G. Vobe removed
lkswagen AG ⇒ page 63 .
d w oes
olks not
byV gu
ara
ed
WARNING nte
ris
tho eo
s au ra
c
Work on
s the fuel tank may only be performed if the counter‐
ce
e
pressure check was successful.

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
WARNING
, is n
h re
hole
spec
Natural gas tanks made of composite material must not be

es, in part or in w
stored without pressure for longer periods of time.

t to the co
If the fuel tank shut-off valve was removed, then it must be

reinstalled immediately after repairs to the fuel tank shut-off
rrectness of i
valve have been completed.

l purpos
After installation of the fuel tank shut-off valve , the fuel tank
needs to be filled with natural gas within 24 hours.
nform
mercia
at
om
2.9.5 Determining residual pressure in natural

on
c
in t
or
gas tank
his
ate
do
priv

um
for
en
ng
t.
yi
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Fuel tank 95
Caddy 2004 ➤ , Caddy 2011 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte

y li
erm
ab
ility

ot p
wit
conversion:
, is n
h re
hole
spec

es, in part or in w
thread) - V.A.G 1274 B/13-

t to the co

rrectness of i

l purpos

nform
ercia
⇒ page 79 .
m
at

om
ion
version:
c
in t
or
his
ate
do
riv

p
cum
or
1274 B/13 A-
f
en
ng
t.
yi Co
♦ Determine version of adapter for counterpressure check on Cop py
t. rig
natural gas tank ⇒ page 79 . opyri
gh by
Vo
ht
c by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e nte
horis Caddy 2004 ➤ , Caddy 2011 ➤ eo
ut
Fuel supplysssystem - natural gas engines - Edition 09.2016 r ac
a
ce
e
nl
pt
du
an
itte
y li
Note
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
set - VAS 6122- .
♦ The only adapter that may be used is the adapter for counter‐
nf
ercia
o
pressure check on natural gas tank - V.A.G 1274 B/12 A- .
rm
m
Older versions must be converted accordingly.
atio
om
n in
or c
Test precondition:
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t.
rig
gh ht
yri by
tem ⇒ page 1 . op Vo
by c lksw
cted agen
Prote
AG.
Note

⇒ page 80 .
WARNING
nected.
(self test) beforehand.

gas).
2. Fuel tank 97
Caddy 2004 ➤ , Caddy 2011 ➤
Version 1
wheel - T50026- .
– Close shut-off valve by turning in clockwise direction -arrow-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
Version 2
ce
le
un
pt
an
d
itte
– Close shut-off valves -2- on all fuel tanks (natural gas) using
y li
erm
ab
commercially available spanner.
ility
ot p
– Close shut-off valve by turning in clockwise direction -arrow-.
wit
is n
h re
ole,
spec
⇒ page 85 .
t to the co
rrectness o
cial p
f
Performing counterpressure check:
inform
mer
atio
WARNING
om
n
c
i
or
n thi

te
sd
a
on the fuel tank shut-off valve .

iv
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Connect adapter for back pressure test on natural gas tank to

cooling system tester - V.A.G 1274 B- -2- on fuel tank shut-off
valve -1-.
– In the case of fuel tank shut-off valves with 2 connections, each
ing cap.
– Use hand wheel - T50026- -3- to carefully open mechanical
shut-off valve on fuel tank shut-off valve -1-.
– Carefully open mechanical shut-off valve on fuel tank shut-off
valve .

Caddy 2004 ➤ , Caddy 2011 ➤
– Close shut-off tap -arrow- on adapter for counterpressure

check on natural gas tank -2-. Lever is then at right angle to
direction of flow.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
1274 B- .
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Fuel tank 99
Caddy 2004 ➤ , Caddy 2011 ➤
– Open shut-off tap -arrow- on adapter for counterpressure

check on natural gas tank -2-.
If pressure does not drop below 1.0 bar immediately:
The pressure in the fuel tank is too high because the fuel tank has
not been emptied completely.en AG. V
olkswagen AG
ag does
ksw not
y Vol gu
b ara
WARNING
ris
ed nte
tho eo
au ra
If the pressure
ss does not drop due to excessive pressure in the c
ce
le
fuel tank, the fuel tank must be emptied again and the coun‐
un
pt
terpressure check must be repeated before continuing work on
an
d
itte
y li
the system.
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
s

s o
cial p
f in
Do not continue work on fuel tank.

form
mer
If pressure drops very slowly:

atio
om
n
c

i
or
n thi
e

t
sd
va
it if necessary.
i
o
pr
cum
r
fo
– Check connection between sealing cap of adapter for back

en
ng
t.
yi Co
pressure check on natural gas tank and fuel tank shut-off Cop py
valve , and tighten if necessary.
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
If pressure drops below 1.0 bar immediately:

– Repeat counterpressure check to verify that the previous
counterpressure check has been performed correctly
⇒ page 92 .
Note
♦ Upon completion of the counterpressure check, operate the

cooling system tester - V.A.G 1274 B- several times.
♦ No pressure must build up while doing so.
♦ Air can be heard to flow into the fuel tank.
♦ If pressure builds up, repeat the back pressure test
⇒ page 92 .
The fuel tank has been emptied sufficiently, and the pressure has
been released.
The fuel tank shut-off valve can be removed ⇒ page 63 .
WARNING
Work on the fuel tank may only be performed if the counter‐

pressure check was successful.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Fuel tank 101

Caddy 2004 ➤ , Caddy 2011 ➤
3 Fuel delivery unit, fuel gauge sender

⇒ “3.1 Assembly overview - fuel delivery unit and fuel gauge
sender”, page 102
⇒ “3.2 Removing and installing fuel delivery unit, fuel gauge send‐
er”, page 103
⇒ “3.3 Removing and installing fuel gauge sender G ”,
page 105
3.1 Assembly overview - fuel delivery unit

and fuel gauge sender
⇒ “3.1.1 Assembly overview - fuel delivery unit and fuel gauge
sender”, page 102
⇒ “3.1.2 Installation position of fuel delivery unit”, page 103
3.1.1 Assembly overview - fuel delivery unit and fuel gauge sender
1 - Fuel tank
❑ Assembly overview
⇒ page 21
❑ Removing and installing lkswage es n
o ot g
⇒ page 60 byV ua
d ran
ir se tee
o
2 - Sealing ring auth or
ac
ss
❑ Renewing
ce
e
nl
pt
du
❑ When installing, fit dry in

an
itte
y li
fuel tank opening.

erm
ab
❑ Moisten with fuel only

ility
ot p
when installing flange.

wit
, is n
h re
hole
3 - Fuel delivery unit

spec
es, in part or in w

t to the co
⇒ page 103
rrectness of i
❑ black
l purpos
❑ From fuel tank

nform
ercia
5 - Fuel return pipe

m
at
om
io
❑ blue
n
c
in t
or
❑ To fuel tank
his
ate
do
riv

p
cum
or
f
en
ng
t.
yi Co
6 - Locking ring Cop py
t. rig
gh ht
yri
7 - Nut p by
co Vo
by lksw
cted
❑ Qty. 8
agen
Prote AG.
❑ 10 Nm
8 - Fuel line
❑ To metering pump -
V54- for auxiliary heater
❑ Depending on vehicle equipment
9 - Fuel gauge sender - G-

Caddy 2004 ➤ , Caddy 2011 ➤
3.1.2 Installation position of fuel delivery unit

Observe marking -arrow- (points forwards) on fuel delivery unit
and securing ring -1-.
Note
The fuel delivery unit flange can only be installed in this position.
Return line blue or with blue marking -1-.
Supply line (black) -2-.
3.2 Removing and installing fuel delivery

unit, fuel gauge
gen AG
. Volkswsender
agen AG
d
wa oes
olks no
Special tools dand
by workshop equipment required guar
V t
e an
ris tee
♦ Torque
ut wrench - V.A.G 1331-
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The fuel delivery unit can only be removed or installed with the
n
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3. Fuel delivery unit, fuel gauge sender 103

Caddy 2004 ➤ , Caddy 2011 ➤
WARNING
Fuel supply lines are under pressure! Wear protective goggles

and protective clothing to avoid injury and contact with the skin. AG. Volkswagen AG d
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Press in securing ring to release the fuel lines.
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WARNING
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A filled fuel tank must be placed on a level surface to ensure
the fuel delivery unit can be removed without danger. Wear
protective goggles and protective clothing to avoid injury and
ss
contact with the skin.
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– Loosen nuts of securing ring -arrow-.

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– Remove fuel delivery unit and seal from opening in fuel tank.
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♦ When inserting the fuel delivery unit, ensure that the fuel
gauge sender - G- is not bent.
♦ Insert seal for fuel delivery unit dry into opening of fuel tank.
♦ Moisten seal with fuel only when installing fuel delivery unit.
♦ Do not interchange supply and return lines.
Observe markings on fuel delivery unit and securing ring

⇒ page 103 .
– Push on fuel lines -1- (blue return line) and -2- (black supply
line).
Torque settings
♦ ⇒ page 21

Caddy 2004 ➤ , Caddy 2011 ➤
3.3 Removing and installing fuel gauge

sender - G-
Removing
– Remove fuel delivery unit ⇒ page 103 .
– Release and pull off connectors -arrows-.
– Mark contacts -1- to -3- for reinstallation.
– Lift securing tabs -4- and -5- using a screwdriver, and pull off
fuel gauge sender - G- downwards -arrow-.
Installing
– Insert fuel gauge sender - G- into guides on fuel delivery unit
and press upwards until it engages.
– Connect connector and ensure secure engagement.
– Install fuel delivery unit ⇒ page 103 .
Torque settings
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3. Fuel delivery unit, fuel gauge sender 105

Caddy 2004 ➤ , Caddy 2011 ➤
4 Plug-in connectors
⇒ “4.1 Separating plug-in connectors”, page 106
4.1 Separating plug-in connectors

♦ Lever - T10468-
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♦ The plug-in connectors 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
rrectne
⇒ page 106 .
♦ Plug-in connectors for fuel lines must engage »audibly« when
ss
joined.
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♦ Ensure plug-in connector is secured properly by pulling it.
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Colour assignment
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Plug-in connector Colour code on plug-in connector
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WARNING


Caddy 2004 ➤ , Caddy 2011 ➤
Variant 1
Plug-in connector with release buttons -arrows- on right and left
Open
It is necessary to counterhold the separating point for fuel -1- in
the engine compartment.
– Insert lever - T10468- between heat shield and stop -arrow- of
fuel line -2- and counterhold. agen
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Continuation for all separating points of fuel system:
– Push plug-in connector -1- in -direction of arrow A-.
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– Press and hold release buttons.
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– Pull plug-in connector -1- off fuel line -2- in
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-direction of arrow B-.

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Note colour assignment during installation ⇒ page 106 .
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Plug-in connectors for fuel lines must engage »audibly« when

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– Ensure plug-in connector is secured properly by pulling it. C py
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4. Plug-in connectors 107

Caddy 2004 ➤ , Caddy 2011 ➤
Version 2
Plug-in connector with pull-release mechanism -arrow-.
Open
– Push plug-in connector -1- in -direction of arrow A-.
– Pull pull-release mechanism -2- in -direction of arrow B-.
– Pull plug-in connector -1- off fuel line -3- in
-direction of arrow B-.
joined.
– Ensure plug-in connector is secured properly by pulling it.
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Version 3
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Plug-in connector with button in front -arrow-
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Plug-in connector with release button -arrows- on right and left:

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– Push plug-in connector in -direction of arrow A-.

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– Press release buttons -arrows- and pull off plug-in connector.

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Caddy 2004 ➤ , Caddy 2011 ➤
Version 5
Plug-in connector with release buttons -arrows- on
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Plug-in connector with release buttons -arrows- on right and left:
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– Push plug-in connector -1- in -direction of arrow- and maintain

pressure.
nform
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– Press release buttons -arrows- and pull off plug-in connector.

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– Press plug-in connector -1- in -direction of arrow A- and main‐

tain pressure.
– Press release button -2- in -direction of arrow B- and pull off
plug-in connector -1-.
joined.
4. Plug-in connectors 109

Caddy 2004 ➤ , Caddy 2011 ➤
5 fuel filter.
⇒ “5.1 Assembly overview - fuel filter”, page 110
⇒ “5.2 Removing and installing fuel filter”, page 110
5.1 Assembly overview - fuel filter
1 - fuel filter.
❑ With pressure regulator.
❑ Direction of flow is
marked with arrows
❑ Do not interchange con‐
nections
❑ Installation position: pin
on filter housing must
engage in notch of guide
in filter bracket
⇒ page 112 .
⇒ page 110
2 - Cable tie
❑ black
❑ From fuel tank
4 - Fuel return pipe
❑ blue
❑ To fuel tank
❑ To pull off, press release AG. Volkswagen AG d
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❑ black ss au ra
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❑ To engine
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6 - Bolt
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❑ 3 Nm
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7 - Holder
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❑ For fuel filter.

❑ Secured to fuel tank.
rrectne
5.2 Removing and installing fuel filter

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110
Prote AG.
Caddy 2004 ➤ , Caddy 2011 ➤
♦ Drip tray, e.g. drip tray for workshop hoist - VAS 6208-
Removing
AG. Volkswagen A
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– Observe rules
by
Volfor cleanliness ⇒ page 7 . ot gu
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– Observetho safety precautions when working on natural
ri tee gas sys‐
or
tems a⇒ page 1 .
u ac
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– Place drip tray - V.A.G 1306- or drip tray for workshop crane -
nl
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VAS 6208- beneath fuel filter.

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WARNING
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Fuel system is under pressure! Wear protective goggles and

spec
protective clothing to avoid injury and contact with the skin.

es, in part or in w
t to the co
Wrap a cloth around the connection before loosening hose

connections. Then release pressure by carefully pulling hose
off connection.
rrectness of i
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– Press release button, and pull off fuel lines -1-, -3- and -5-
⇒ page 106 .
nf
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– Unscrew bolt -2-.

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– Open cable ties -4-.

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– Remove fuel filter.

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Direction of flow is indicated with an arrow on filter housing.
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– Fuel system ⇒ Rep. gr. 24 ; Injection system; Filling/bleeding
fuel system .
5. fuel filter. 111

Caddy 2004 ➤ , Caddy 2011 ➤
Installation position
Pin -2- on filter housing must engage in notch of guide -1- on filter
bracket.
Torque settings
♦ ⇒ “5.1 Assembly overview - fuel filter”, page 110
AG. Volkswagen AG d
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Caddy 2004 ➤ , Caddy 2011 ➤
6 Activated charcoal filter system

⇒ “6.1 Assembly overview - activated charcoal filter system”, page
113 gen AG
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⇒ “6.2 Checking fuel tank breather”,
db
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6.1 Assembly
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overview - activated charcoal filter system au
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1 - Activated charcoal filter
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❑ Location: on fuel tank.
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3 - Pressure retention valve
hole
spec
with connecting hose
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t to the co
❑ Closes tank breather
when activated charcoal
filter solenoid valve 1 -
rrectness of i
N80- is open and intake
manifold vacuum is
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4 - Connection hose
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5 - To activated charcoal filter

m
at
solenoid valve 1 - N80-
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c
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6 - Clip
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7 - Activated charcoal filter sol‐

p
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enoid valve 1 - N80-

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❑ On upper part of intake
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6.2 Checking fuel tank breather

6. Activated charcoal filter system 113

Caddy 2004 ➤ , Caddy 2011 ➤
♦ Hand operated vacuum pump - VAS 6213-
Prerequisites for check

• Ignition must be switched off.
Test sequence AG. Volkswagen AG d
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– First, disconnect white breather hose off activated
d byV charcoal gu
ara
filter ⇒ Item 4 (page 113) . Cutting orise nte
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– Then, connect hand vacuum pump -ssVAS 6213- as shown to
a c
hose -1-.
ce
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– Operate hand vacuum pump - VAS 6213- several times. There
itte
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must be no development of vacuum.
ab
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If vacuum builds up:
wit
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– Check breather hose -3- on activated charcoal filter -2- for
hole
spec
soiling and clean if necessary.
es, in part or in w
t to the co
If vacuum does not build up:
– Hold breather hose -3- shut and operate vacuum pump again
rrectness of i
several times. Vacuum must build up.
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If vacuum does not build up:

– Renew activated charcoal filter -2-.
nf
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Caddy 2004 ➤ , Caddy 2011 ➤
7 Accelerator pedal
⇒ “7.1 Assembly overview - accelerator module”, page 115
⇒ “7.2 Removing and installing accelerator module with acceler‐
ator position sender G79 / G185 ”, page 115
7.1 Assembly overview - accelerator module
1 - Connector
❑ black
❑ 6-pin lkswage es n
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2 - Accelerator positionrisender
se
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- G79- with accelerator
uth posi‐
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❑ Not adjustable.
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❑ The accelerator position

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sender transmits the
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ility
driver's requirement to
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the engine control unit.
is n
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❑ -A- openings for release
spec
tool - T10269- or release
tool - T10297-
t to the co
⇒ page 115
rrectne
3 - Bolt
❑ 10 Nm
ss o
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4 - Cap f inform
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7.2 Removing and installing accelerator

module with accelerator position sender
-G79- / G185
7. Accelerator pedal 115

Caddy 2004 ➤ , Caddy 2011 ➤
♦ For left-hand drive vehicles: release tool - T10269-
lkswage es n
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tho
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♦ For right-hand drive vehicles: release tool - T10297-
pt
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spec
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– Remove cover for steering column -arrows-.
form
mer
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– Lever out cap ⇒ Item 4 (page 115) using a screwdriver.
om
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c
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– Unscrew securing bolt ⇒ Item 3 (page 115) .
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– Push release tool - T10269- (for RHD vehicles release tool -

T10297- ) into intended holes to stop as shown.
– Remove accelerator module.
– Release and pull off connector.
Installing

AG. Volkswagen AG d
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– Connect connector
ss au
-2- to accelerator pedal module. ra
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– Fit line guide -1-.
nl
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– Push accelerator pedal module onto retaining pins -6-.
erm
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– Insert centring pin -7- into hole in underbody.
wit
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– Secure accelerator pedal module with bolt -3-.
hole
spec
– Fit cap -4-.
es, in part or in w
t to the co
– Reinstall cover for steering column.
Torque settings
rrectness of i
♦ ⇒ “7.1 Assembly overview - accelerator module”, page 115
l purpos
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7. Accelerator pedal 117

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Caddy 2004 ➤ , Caddy 2011 ➤ tho tee
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Fuel supply system - natural gas engines - Edition
ss
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09.2016 ac
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8 Fuel pump
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⇒ “8.1 Checking fuel system pressurisation pump G6 ”,
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page 118
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spec
8.1 Checking fuel system pressurisation
t to the co
pump - G6-
⇒ “8.1.1 Checking function and voltage supply”, page 118
rrectne
⇒ “8.1.2 Checking fuel pressure”, page 120
s
⇒ “8.1.3 Checking holding pressure”, page 123
s o
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⇒ “8.1.4 Checking fuel delivery rate”, page 126
nform
mer
⇒ “8.1.5 Checking current consumption”, page 132
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8.1.1 Checking function and voltage supply
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♦ Multimeter, e.g. hand-held multimeter - V.A.G 1526E- yi

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♦ Adapter set - V.A.G 1594C-
♦ Voltage tester - V.A.G 1527B- or voltage tester - VAS 6839-

Caddy 2004 ➤ , Caddy 2011 ➤
♦ Remote control for V.A.G 1348 - V.A.G 1348/3A-
♦ Test probe - V.A.G 1527B/1-

Test conditions:
• Battery voltage must be at least 11.5 V. If necessary, charge
battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Charging
battery .
wage es n
• Fuel pump control unit - J538- OK ⇒ Vehicle diagnosticy Vtester.
olks ot g
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Test sequence thoris tee
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– Observe safety precautions ⇒ page 1 . ss
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tem ⇒ page 1 .
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• Battery voltage at least 11.5 V.
h re
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spec
• Fuse SB33 at position F33 in electronics box in engine com‐
es, in part or in w
partment OK
t to the co
• Ignition switched off.
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– Switch on ignition. The fuel pump must run.
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Note
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The fuel pump runs very quietly.
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– Switch off ignition.

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If the fuel pump does not start:

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– Open cover for relay and fuse holder of electronics box in en‐
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– Pull fuse SB33 out of socket F33 of fuse holder.
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– Connect remote control - V.A.G 1348/3 A- with adapter cable
- V.A.G 1348/3-3- to right terminal of fuse socket F33.
– Tape off 2nd connector contact of adapter cable -
V.A.G 1348/3-3- with insulating tape -arrow- to prevent short
circuits.
– Connect crocodile clip to vehicle battery (+).
– Press remote control switch.
If fuel pump runs:
– Check or, if necessary, renew fuel pump relay - J17- .
If fuel pump does not run:
8. Fuel pump 119

Caddy 2004 ➤ , Caddy 2011 ➤
– Pull 5-pin connector off fuel delivery unit flange.
Note
To reach 5-pin connector, release fuel tank and lower slightly

⇒ page 60 .
– Connect voltage tester - V.A.G 1527 B- to outer contacts of

connector using auxiliary cables from auxiliary measuring set
- V.A.G 1594 C- .
– Press remote control - V.A.G 1348/3A- switch.
If LED does not light up:
– Locate and eliminate open circuit referring to current flow di‐
agram ⇒ Current flow diagrams, Electrical fault findingagand
en AG. V
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does
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LED lights up (voltage supply OK): horis tee
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– Release locking ring at connections -arrows-.
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– Check that electrical wires between flange and fuel pump are
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connected.
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If no cable break can be found:
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– Fuel pump is defective; renew fuel delivery unit ⇒ page 103 .
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
8.1.2 Checking fuel pressure
nform
ercia

m
a
com
tion in
♦ Pressure gauge - VAS 6550-
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Test conditions
• Voltage supply OK.
rrectness of i
– Pull off supply line -2-. Separate plug-in connectors
l purpos
⇒ page 106 .
nform
mercia
at
WARNING
om
ion
c
in t
or
his
ate
do
riv

p
cum
for
en
g

n
t.
yi Co
op
and contact with the skin. Wrap a cloth around the connection C py
t. rig
gh ht
pyri by
co Vo
by lksw
cted agen
Prote AG.
– Connect hose - VAS 6550- to connection -A- of pressure tester

- VAS 6550/2- .
– Use hose - VAS 6550- to connect fuel line leading to fuel tank
with pressure tester - VAS 6550/2- .
– Connect hose - VAS 6550/1- to fuel supply line leading to en‐
gine.
– Connect hose - VAS 6550/1- to connection -B- of pressure
tester - VAS 6550- .
– Ensure plug-in connectors are secure properly by pulling.
– Make sure that drain tap -C- on pressure tester -1- is closed.
– Shut-off valves -A- and -B- on pressure tester -1- are open.
gine compartment.
8. Fuel pump 121

Caddy 2004 ➤ , Caddy 2011 ➤

circuits.
Note
The fuel pump is now actuated to build up fuel pressure.
– Read off fuel pressure on pressure gauge.

Specification for engine code BSX: approx. 4.0 bar
If fuel pressure is OK, check holding pressure ⇒ page 123 .
If the specification is exceeded:
– Check return line between fuel filter and fuel pump for kinks
and blockages.
If no fault is detected on fuel line:
– Pressure limiting valve in fuel filter is defective. Renew fuel
filter ⇒ page 110 .
If specification is not obtained
Check fuel pressure before fuel filter by following this procedure:
Checking fuel pressure before fuel filter:

– Pull fuel supply line -arrow- off fuel filter. Separate plug-in con‐
nectors ⇒ page 106 .
AG. Volkswagen AG d
– Collect escaping fuel with a cleaning
lksw cloth.
agen oes
not
o
yV gu
edb ara
ris nte
WARNING tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte

y li
erm
ab
ility

ot p
wit
, is n
h re

hole

spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
– Connect pressure tester - VAS 6550- between fuel filter and

fuel supply line using hose - VAS 6550/1- and hose - VAS
6550/2- .
– Connect hose - VAS 6550/2- to connection -A- of pressure
– Connect hose - VAS 6550/1- to connection -B- of pressure
– Ensure plug-in connectors are secure properly
wage
by
n AG pulling.
. Volkswagen AG
doe
olks s no
yV t gu
edb ara
ris nte
tho eo
au ra
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
If reading matches specification:

– Check fuel line between fuel filter and engine compartment for
nf
ercia
restrictions (kinks) or blockages.
orm
m
atio
– Check fuel line between fuel filter and engine compartment for
om
n in
leaks and damage.
or c
thi
te
If no fault is detected:
sd
iva
o
r
rp
cu
– Fuel filter is blocked. Renew fuel filter ⇒ page 110 .
o
m
f
en
ng
t.
yi Co
– Pressure limiting valve in fuel filter is defective. Renew fuel . Cop py
ht rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Check fuel lines for possible restrictions (kinks) or blockages.
– Check fuel line for leaks and damage.
– Remove fuel delivery unit and check for contamination
⇒ page 103 .
– Ensure that all hoses are properly connected to fuel delivery
unit -arrows-.
– Check fuel lines for leaks and damage.
If no fault is found:
– Fuel pump is defective; renew fuel delivery unit ⇒ page 103 .
8.1.3 Checking holding pressure

8. Fuel pump 123

Caddy 2004 ➤ , Caddy 2011 ➤
Test conditions:
• Voltage supply OK ⇒ page 118 .
• Fuel pressure OK ⇒ page 120 .
AG. Volkswagen AG d
ksw
agen oes
not
tem ⇒ page 1 . y Vol gu
db e
ara
ris nte
– Connect hose - VAS 6550/2- between fuel line ut from fuel tank
ho eo
ra
to shut-off tap -A- of pressure tester - VASs6550-
sa . c
ce
le
– Connect hose - VAS 6550/1- between fuel line leading to en‐

un
pt
an
d
gine and shut-off tap -B- of pressure tester - VAS 6550- .

itte
y li
rm
ab
Test sequence
pe
ility
ot
wit
, is n
h re
gine compartment.
hole
spec
es, in part or in w

t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
124
cted agen
Prote AG.
Caddy 2004 ➤ , Caddy 2011 ➤

circuits.
Note
The fuel pump is now actuated to build up fuel pressure.

AG. Volkswagen AG d
– Read fuel pressure on pressure gauge and observe. lksw
agen oes
not
o
byV gu
Specification for engine code BSX: approx. 4.0 bar rised ara
nte
tho eo
– Release remote control - V.A.G 1348/3A- switch.
s au ra
c
s
ce
e
• Observe pressure drop on pressure gauge. After 10 minutes,

nl
pt
du
the pressure must not drop by more than 1 bar.
an
itte
y li
erm
ab
If the pressure drops:
ility
ot p
wit
– Check all fuel lines for leaks and damage.
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Actuate fuel pump with final control diagnosis to build up fuel
l purpos
pressure.
– After pressure has built up, close shut-off tap -B- of pressure
nf
ercia
tester immediately. Lever is then at right angle to direction of
or
flow.
m
m
atio
m
If the pressure now drops (leak on fuel tank side):

o
n in
or c
thi
e
Check holding pressure on fuel filter ⇒ page 126 .

t
sd
iva
o
r
rp
cu
If the pressure does not drop now (leak on engine side), engine
o
m
f
en
ng
code BSX:
t.
yi Co
Cop py
ht. rig
rig ht
py by
Note co Vo
by lksw
cted agen
Prote AG.
Search for leak on engine side. Repeat holding pressure check.
This time, close shut-off tap -A- to check whether leak actually is
on engine side.
– If there is a leak on engine side, carry out external check of

fuel pipes and fuel lines for leaks.
If no fault can be determined, check injectors for leaks ⇒ Rep.
gr. 24 ; Injectors; Checking injectors :
8. Fuel pump 125

Caddy 2004 ➤ , Caddy 2011 ➤
Checking holding pressure on fuel filter:

WARNING

– Connect pressure tester - VAS 6550- between fuel filter and

fuel supply line using hose - VAS 6550/1- and hose - VAS
6550/2- .
tester - VAS 6550- . olks
wage es n
o V t gu
by ara
– Connect hose - VAS 6550/1- to connection
ris
ed -B- of pressure nte
tester - VAS 6550- . au
tho eo
ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Repeat holding pressure check ⇒ page 124 .

m
a
com
tio
– After pressure has built up, close shut-off tap -A-.

n in
r
te o
thi
– Observe pressure drop on pressure gauge. After 10 minutes,

s
iva
do
pressure must not drop below 3.0 bar.

r
rp
cum
fo
If pressure no longer drops:

en
ng
t.
yi Co
op py
– Check fuel line leading to engine for leaks. t. C rig
gh ht
pyri by
– Check fuel filter for leaks.
o Vo
by c lksw
cted agen
Prote AG.
– Pressure limiting valve in fuel filter is defective. Renew fuel
If the pressure drops:
8.1.4 Checking fuel delivery rate


Caddy 2004 ➤ , Caddy 2011 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
♦ Multimeter, e.g. hand-held multimeter - V.A.G 1526E-

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia

orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
♦ Pressure regulating valve - VAS 6550/4-
♦ Measuring container, capacity: 3 litres
8. Fuel pump 127

Caddy 2004 ➤ , Caddy 2011 ➤
Note agen
AG. Volkswagen AG d
oes
olksw not
V gu
by ara
When driving characteristic problems occur rised
when the fuel tank is nte
a approx. 1/4 filled, then check fuel adelivery rates with approx. 1/
ho eo
ut ra
s c
4 filled tank or less. s
ce
le
un
pt
an
d
itte
Test conditions:
y li
rm
ab
pe
ility
• Voltage supply OK ⇒ page 118 .
ot
wit
, is n
• Fuel pressure OK ⇒ page 120 .
h re
hole
spec
• Battery voltage must be at least 11.5 V. If necessary, charge
es, in part or in w
battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Charging
t to the co
battery .
• Fuse for fuel pump control unit - J538- OK ⇒ Current flow di‐
rrectness of i
agrams, Electrical fault finding and Fitting locations.
l purpos
• Fuel pump control unit - J538- OK ⇒ Vehicle diagnostic tester.

• Fuel pump relay - J17- OK ⇒ Vehicle diagnostic tester
nform
ercia
• Fuel pump fuse OK ⇒ Current flow diagrams, Electrical fault

m
a
finding and Fitting locations
com
tion in
r
• Check that connector is fitted securely by pulling connector

te o
thi
s
without pressing catch. If connector was not inserted correctly,
iva
do
r
repeat functional check of fuel pump.

rp
cum
fo
en
ng
• Filling level in fuel tank above reserve.

t.
yi Co
Cop py
t. rig
Test sequence opyri
gh by
Vo
ht
by c
lksw
cted agen
Prote AG.
tem ⇒ page 1 .
gine compartment.
circuits.
– The quantity delivered by the fuel pump depends on the bat‐
tery voltage. For this reason, connect the multimeter in addi‐
tion.
– Connect multimeter with auxiliary measuring set - V.A.G
1594C- .

Caddy 2004 ➤ , Caddy 2011 ➤
– Pull off supply line -2-. Separate plug-in connectors

⇒ page 106 .
WARNING

– Connect hose - VAS 6550- to connection -A- of pressure tester

- VAS 6550/2- .
– Connect hose - VAS 6550- between fuel line from fuel tank
and pressure tester - VAS 6550/2- .
– Connect pressure regulator valve - VAS 6550/4- to connection
-B- of pressure tester - VAS 6550- .
– Hold end of hose of pressure regulating valve - VAS 6550/4-
in measuring container.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
– Press remote control - V.A.G 1348/3A- .
t to the co
Note
rrectness of i
l purpos
The fuel system pressurisation pump - G6- will be actuated.

nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
8. Fuel pump 129

Caddy 2004 ➤ , Caddy 2011 ➤
– Set pressure of 4.0 bar on pressure regulating valve -arrow-

using adjuster wheel.
– From this point on do not change position of adjuster wheel
anymore. . Volkswage n AG d n AG
oes wage
– Drain measuring ycontainer.
Vol
ks not
gu
d b ara
e
– Press remote horiscontrol for 30 seconds whilst measuring voltage
nte
eo
at fuel pump.
aut ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
– Compare delivered quantity of fuel with specification indicated
h re
hole
in chart.
spec
es, in part or in w
t to the co
Name of axis Unit
Minimum delivery rate cm 3
rrectness of i
Voltage at fuel pump with en‐ Volt
gine not running and pump run‐
l purpos
ning.
Reading example:
nf
ercia
orm
During the test a voltage of 10.5 volts is measured. This equates
m
atio
m
to a minimum delivery rate of approx. 540 cm3 in 30 seconds.

o
n in
or c
thi
te
sd
a

iv
o
r
rp
cu
o
– Open tank flap unit.

f
en
ng
t.
yi Co
op
– Clean area around fuel filler neck. C py
t. rig
gh ht
yri
– Unscrew cap from fuel filler neck -arrow-.
p by
co Vo
by lksw
cted agen
– Repeat fuel delivery rate check ⇒ page 128 .
Prote AG.

– Check fuel tank breather ⇒ page 113 .
Check fuel delivery rate at fuel filter as follows:
Checking fuel delivery rate at fuel filter:

WARNING


Caddy 2004 ➤ , Caddy 2011 ➤
AG. Volkswagen AG d
Fuel supply systemk-swnatural
agen gas engines - oEdition
es n 09.2016
ol ot g
yV ua
db ran
– Connect pressure tester - VAS 6550- to fuel supply ris line -2-
e
by tee
ho
means of hose - VAS 6550/1- . aut or
ac
ss
ce
le
un
pt
an
d
itte
y li
erm
– Connect pressure regulator valve - VAS 6550/4- to connection
ab
ility
-B- of pressure tester - VAS 6550- .
ot p
wit
is n
– Hold end of hose of pressure regulating valve - VAS 6550/4-
h re
ole,
in measuring container.
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
r
p
cum
r
fo
en
ng
– Press remote control - V.A.G 1348/3A- .

t.
yi Co
Cop py
ht. rig
rig ht
py by
o Vo
Note by c lksw
cted agen
Prote AG.
The fuel system pressurisation pump - G6- will be actuated.
– Set pressure of 4.0 bar on pressure regulating valve -arrow-

using adjuster wheel.
– From this point on do not change position of adjuster wheel
anymore.
– Drain measuring container.
– Press remote control for 60 seconds whilst measuring voltage
at fuel pump.
– Check fuel line leading to engine for possible restrictions
(kinks) or blockages.
– Check fuel line leading to engine for leaks and damage.
– Renew fuel filter ⇒ page 110 .
8. Fuel pump 131

Caddy 2004 ➤ , Caddy 2011 ➤

– Remove fuel delivery unit ⇒ page 103 .
– Remove fuel delivery unit and check filter strainer for dirt.
– Check that all fuel delivery unit -1- hose connections
-arrows- are connected.
– Check current draw of fuel pump ⇒ page 132 .
If no fault was detected in the current draw:
– Renew fuel delivery unit ⇒ page 103 .
If fuel delivery rate has been attained, but nevertheless you sus‐
pect a fuel supply system fault (e.g. intermittent failure of fuel
supply system):
– Check current draw of fuel pump ⇒ page 132 .
8.1.5 Checking current consumption

♦ Multimeter, e.g. hand-held multimeter - V.A.G 1526E-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
♦ Multimeter - V.A.G 1715-
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
horis nte
eo Caddy 2004 ➤ , Caddy 2011 ➤
aut Fuel supply system ra - natural gas engines - Edition 09.2016
ss c
ce
e
nl
pt
♦ Pickup clamp e.g. pickup clamp - V.A.G 1526E/2-
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
Note
om
n in
or c
thi
♦ Plug-in connectors for fuel lines must engage »audibly« when
te
sd
a
joined.
iv
o
r
rp
cu
o
m
♦ Note colour assignment when installing the plug-in connectors
f
en
ng
t.
yi
⇒ page 106 .
Co
Cop py
ht. rig
♦ Ensure plug-in connector is secured properly by pulling it.
rig ht
py by
co Vo
by lksw
♦ Separate plug-in connectors ⇒ page 106 .
cted agen
Prote AG.

tem ⇒ page 1 .
– Using pick-up clamp, connect multimeter - V.A.G 1715- on
underbody to wiring harness leading to fuel tank.
– Run engine at idling speed.
– Measure current draw of fuel pump.
♦ Specification: max. 9 amps.
The starting current for the fuel pump can be briefly above spec‐
ifications when starting the engine.
Note
If the fuel system malfunction is intermittent, the check can be

performed during a road test, but a 2nd person is required for this.
If the current draw is exceeded:

– Fuel pump is defective, renew fuel delivery unit ⇒ page 103 .
8. Fuel pump 133

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Service

Service Department. Technical Information

All rights reserved.

Copyright © 2016 Volkswagen AG, Wolfsburg D4B804C91DD

4.3 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4.4 Pipe/wire routing and attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4.5 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

5 Checking gas system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1.1 Overview of fitting locations - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.2 Assembly overview - protective covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.3 Assembly overview - fuel tank shut-off valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2.4 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

2.5 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

2.6 Removing and installing fuel tank shut-off valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

valve or natural gas tank:

Release pressure in high-pressure line ⇒ page 75 .

• The mechanic may be the source for electrostatic dis‐

Before evacuating natural gas tanks, make sure to comply with

• Contact your importer for further procedure regarding the

natural gas tanks that are still filled with fuel.

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

♦ Route high-pressure lines in their original positions.

♦ Ensure lines have sufficient clearance to all moving or hot

♦ Never attempt to reshape high-pressure lines of natural

2 Rep. gr.00 - Technical data

1.2 Safety regulations for working on fuel supply

and carefully loosen the connection.

and cause a fire.

Malfunction caused by air in the fuel supply system

– Fill fuel take-off pipe with fuel.

1.3 Safety measures when working on vehicles with a start/stop system

4 Rep. gr.00 - Technical data

Natural gas Up to 1401)

calorific gas: methane content 87.1 - 98.0 %) may vary in different

attention to the following “rules”:

♦ Place removed parts on a clean surface and cover them over.

have been kept unpackaged (for example in toolboxes).

example from engine bung set - VAS 6122- .

♦ Protect disconnected electrical connections from dirt and wa‐

ter and only reconnect in dry condition.

6 Rep. gr.00 - Technical data

4.1 Rules for cleanliness

4.1.1 Rules for cleanliness when working on

♦ If repair work cannot be performed immediately, cover new

aging until immediately before installing. Do not use any parts

which have not been stored in their packaging (e.g. in a tool

♦ If system is open, do not work with compressed air. Do not

♦ Protect disconnected electrical connections from dirt and wa‐

4.1.2 Rules for cleanliness when working on

When working on the natural gas supply, pay careful attention to

the following “rules” for cleanliness:

♦ Thoroughly clean all joints and surrounding areas before dis‐

4.2 General information

4.2.1 General notes on ignition system

♦ If, after fault finding, repairs or component tests, the engine

♦ Fault rectification: adapting engine control unit ⇒ Vehicle di‐

♦ If fuel system has been opened, it must be bled before engine

use of crimp-type or screw-type clips is not permissible.

♦ The battery must be disconnected only with ignition switched