Recall - Fuel Supply Line Clamp Inspection/Replacement: Overview
Subject: 2005 Model Year Volkswagen New Jetta Vehicles with a 2.5L Gasoline EngineInspect Engine Compartment Fuel Supply Line Clamp and Replace if Necessary
This is to inform you of a safety recall involving some 2005 model year New Jetta vehicles equipped with a 2.5L gasoline engine.
June 2005
Campaign Work Procedure
Parts:
Special Tools and Equipment:
- VAS 5024A spring type clip pliers
- V.A.G 1318/20 adapter or equivalent
- V.A.G 1348/3A remote control or equivalent
- V.A.G 1348/3-3 adapter cable or equivalent
- VAS 5226 suction pump or equivalent
Work Sequence:
Section A - Check Fuel Feed Hose and Spring Clip
- Switch ignition off and open hood
- Pull engine cover out of retainers first at front -arrow 1-, then at right rear -arrow 2- and lastly at left rear -arrow 3-
- Carefully pivot engine cover out from rear area
- Lift left side -arrow 1 and 2- of engine cover up to allow inspection of fuel feed hose to fuel rail connection without disconnecting MAF sensor or air intake tube
- Perform the following four checks. If any one check is not met proceed to Section B and replace fuel feed hose spring clip
WARNING: Use hands only while trying to rotate fuel feed hose, as damage may occur to the fuel feed hose when using tools.
Check 1
- Attempt to rotate fuel feed hose on fuel rail
- If hose does not rotate on fuel rail proceed to Check 2
- If hose rotates on fuel rail, proceed to Section B
Check 2
NOTE: Pictures are shown with parts off the vehicle for demonstration purposes
- Check that fuel feed hose is fully seated on fuel rail -arrow 1-
- If hose is correctly seated proceed to Check 3
- If hose is incorrectly seated -arrow 2- proceed to Section B
Check 3
- Check spring clip release tabs -arrow 1- to ensure they are centered over box with arrow on hose -arrow 2-
- If spring clip is properly positioned proceed to Check 4
- If spring clip not properly positioned proceed to Section B
Check 4
- Measure distance from clip on fuel feed hose to the fuel rail base
- If measurement is between 18mm and 23mm no further work required
- Position engine cover correctly in fastening points and push it in by hand
- Close hood
WORK COMPLETE
- If measurement is more than 23mm or less than 18mm from fuel rail base, proceed to Section B
Section B - Replace Fuel Feed Hose Spring Clip
WARNING:
- Fuel supply line is under pressure. Wear eye protection and protective clothing in order to avoid injuries from contact with fuel. Before removing a hose connection wrap a cloth around the connection. Release pressure by carefully pulling hose off connection. Observe rules for cleanliness
- Prior to starting work on fuel system remove two fuses to prevent activation of fuel pump
- Remove left instrument panel side cover -1- by inserting screwdriver into recess -2- and pry off cover -1- in -direction of arrow-
- Remove blue 15 amp fuse SC 27 -circle-
- Slide securing bracket -1- in direction of arrows and remove E-box cover -2- upward
- Remove blue 15 amp fuse SB 33 -circle-
- Disconnect MAF sensor connector -1- and intake air duct -2-
- Remove bolts -3- and pull off intake air duct
- Lift engine cover with air filter and remove from engine compartment
NOTE: To avoid contamination of fuel DO NOT use any lubricant fluid when removing and installing the fuel feed hose on the fuel rail
- Using VAS 5024A, release spring clip and remove fuel line from fuel rail
- Remove spring clip from fuel line and dispose of properly
- Using VAS 5024A, install new spring clip (part number N 909 865 01) on fuel feed line
- Push fuel feed line with spring clip on fuel rail until fully seated
- Release tabs of spring clip must be centered over the box with arrow on fuel line between 20mm and 22mm from fuel rail base
- Connect remote control connection V.A.G 1348/3A with adapter cable V.A.G 1348/3-3 to right terminal of fuse socket F 33
- Using insulating tape, tape over second contact of adapter cable V.A.G 1348/3-3 to prevent a short circuit -arrow-
- Connect alligator clip to vehicle battery B+
- Unscrew cap -arrow- from bleed valve
- Turn valve (at T-piece) counterclockwise until completely open
- Screw adapter V.A.G 1318/20-1 onto adapter V.A.G 1318/20
- Screw adapter V.A.G 1318/20 hand tight onto bleeder valve
- Connect hose from suction pump VAS 5226, as illustrated
- Turn valve (on T-piece) clockwise into bleed valve to stop
- Check adapter and hose connection for leaks
- Operate remote control V.A.G 1348/3A until fuel flows out of bleeder valve without bubbles
- Turn valve (at T-piece) counterclockwise until completely open again
- Clamp off hose from suction pump VAS 5226 with hose clamp and pull hose off from adapter V.A.G 1318/20-1
- Reinstall cap onto bleed valve
- Remove remote control connection V.A.G 1348/3A with adapter cable V.A.G 1348/3-3
- Position engine cover with air filter correctly in fastening points and push it in by hand
- Reconnect MAF sensor connector -1- and intake air duct -2-
- Install intake air duct and bolts -3-
NOTE: Ensure correct position of seal on E-box when reinstalling cover to prevent water entry
- Reinstall blue 15 amp fuse SB 33 and install Ebox cover
- Close hood
- Reinstall blue 15 amp fuse SC 27 and install instrument panel side cover
WORK COMPLETE