Fuel System, Checking For Leaks: Notes

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Special Tools And Workshop Equipment Required

Evaporative Emissions Tester KLI 9210
Evaporative Emissions Tester - Adapter 55 KLI 9210/55-1
Vehicle Diagnostic Tester
Hose Clamps - Up To 25mm 3094

Test Conditions

Guided Fault Finding was performed using the Vehicle Diagnostic Tester.
The Leak Detection Pump -V144- detected a leak.

Procedure

Connector	Color Marking on the Connector Coupling
Fuel supply	Black
Fuel Return Line	Blue
Ventilation	White beige
Vacuum	Green

Evaporative Emissions Tester KLI 9210 Preparation

NOTE:

Depending on the version, the appearance of the Evaporative Emissions Tester KLI 9210 may vary.

-- Check the Evaporative Emissions Tester KLI 9210 to make sure there is enough fluid in the smoke generator.

-- Set the valve -D- to "Hold".

Fig 1: Checking Evaporative Emissions Tester KLI 9210 DLX To Determine Whether There Is Enough Fluid In Smoke Generator

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Open the nitrogen bottle -H-.

-- Connect the measuring hose -G- to the self-test connection -B-.

-- Set the valve -D- to "Test".

-- Using the pressure reducer -J-, adjust the pressure to 25 mbar (10 in. H2O).

-- Set the valve -D- to "Hold".

The pressure must now be maintained for a minimum of 2 minutes.

If the pressure is not maintained, check the tester.

Fuel System, Checking for Leaks

Fig 2: Connecting Adapter For Evaporative Emission Tester KLI 9210/55-1 To Ventilation Line

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Connect the Evaporative Emissions Tester - Adapter 55KLI 9210/55-1 to the vent lines -A- "white markings" as illustrated. Refer to FUEL SYSTEM, CHECKING FOR LEAKS .

-- Connect the measuring hose -G- on the Evaporative Emissions Tester KLI 9210 to the Evaporative Emissions Tester - Adapter 55 KLI 9210/55-1.

Fig 3: Connecting Measuring Hose From Evaporative Emissions Tester KLI 9210 To Adapter For Evaporative Emission Tester KLI 9210/55-1

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Connect the Vehicle Diagnostic Tester to the vehicle.

Fig 4: Connecting Evaporative Emissions Tester To Vehicle

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The procedure changed when the electrical Leak Detection Pump -V144- was introduced.

-- Switch the ignition on.

The engine may be not running.

-- Select the Guided Functions operating mode on the Vehicle Diagnostic Tester.

-- Select the Check Tank Ventilation System for Leaks .

-- Start the test.

-- Watch the pressure gauge on the Evaporative Emissions Tester KLI 9210.

The Leak Detection Pump - V144- must pump the fuel system pressure up to at least 25 mbar (25.40 cm. H2O).

The Minimum Pressure Is Not Reached and the Pressure Reached Decreases Immediately:

-- Clamp off the hose to the EVAP Canister Purge Regulator Valve 1 -N80- with a hose clamp -arrow-.

Fig 5: Clamping Off Hose To EVAP Canister Purge Regulator Valve 1 -N80-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Repeat the test. If the minimum pressure is now reached: Replace EVAP Canister Purge Regulator Valve 1 -N80-.

The Minimum Pressure Is Not Reached Again Or the Pressure Reached Decreases Immediately:

-- There is a leak in the fuel system: Perform the test "Check for Leak In Fuel System". Refer to FUEL SYSTEM, CHECKING FOR LEAKS .