Fuel System, Checking For Leaks: Notes

WARNING: This page is about a different car, the 2009 Volkswagen Rabbit, 2008 Volkswagen Rabbit, 2007 Volkswagen Rabbit, and 2006 Volkswagen Rabbit. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Evaporative Emissions Tester KLI 9210
Adapter for Evap. Tester KLI 9210/55-1
Vehicle Diagnostic Tester
Hose Clamps up to 25 mm Dia.3094

The connector couplings, for the fuel, vacuum and ventilation lines are color coded. There is either a colored dot on the connector or the release button is the corresponding color.

Connector Coupling	Color Code
Fuel supply	Black
Fuel return line	Blue
Ventilation	White, Beige
Vacuum	Green

Test Conditions

The leak detection pump -V144- detected a leak.
Perform "Guided Fault Finding" using the vehicle diagnostic tester.

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 determine whether there is enough fluid in the smoke generator.

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

Fig 1: Identifying Evaporative Emission (EVAP) Canister Purge Regulator Components

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-- Open the nitrogen bottle -H-.

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

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

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

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

-- The pressure must now be maintained a minimum of 2 minutes. If the pressure is not maintained, check the tester.

Fuel System, Checking for Leaks

-- Connect the adapter for evap. tester KLI 9210/55-1 to the ventilation line -A- as shown. (Color identification: white).

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

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-- Connect the measuring hose -G- from the evaporative emissions tester KLI 9210 to the adapter for evap. tester 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

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

-- Connect the vehicle diagnostic tester -1- to the vehicle.

Fig 4: Connecting Evaporative Emissions Tester To Vehicle

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-- Start the engine and run at idle speed.

-- Select Guided Functions on the vehicle diagnostic tester.

-- Select "Check tank ventilation system for leaks".

-- Start the test.

-- While the test runs, observe the pressure gauge on the evaporative emissions tester KLI 9210.

The leak detection pump must pump the fuel system up to a minimum of 7 in. H2O (18 mbar).

If the minimum pressure is not reached, but the pressure reached does not decrease:

-- Turn the ignition off and perform a pressure retention test. Refer to FUEL SYSTEM, CHECKING FOR LEAKS => Pressure Retention Test . If no decrease in pressure is observed: Check the leak detection pump vacuum supply. Refer to LEAK DETECTION PUMP, CHECKING VACUUM SUPPLY .

If 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- using a hose clamp up to 25 mm dia.3094 -arrow-.

Fig 5: Clamping Off Hose To EVAP Canister Purge Regulator Valve 1 -N80- Using Hose Clamps Up To 25 Mm Dia. 3094

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-- Repeat the test. If the minimum pressure is not reached: Replace the EVAP canister purge regulator valve 1.

If the minimum pressure is not reached again and the pressure reached decreases immediately:

-- There is a leak in the fuel system: Perform the "Fuel System Leak Test". Refer to FUEL SYSTEM LEAK TEST .

If the minimum pressure is reached, turn the ignition off.

The valve in the leak detection pump is now closed and the pressure is maintained.

-- Observe the pressure gauge:

If the pressure does not decrease, perform a pressure retention test to locate any possible pinhole leaks. Refer to FUEL SYSTEM, CHECKING FOR LEAKS => Pressure Retention Test .

If the pressure decreased, clamp off the hose to the EVAP canister purge regulator valve 1 using a hose clamp up to 25 mm dia.3094 -arrow-.

Fig 6: Clamping Off Hose To EVAP Canister Purge Regulator Valve 1 -N80- Using Hose Clamps Up To 25 Mm Dia. 3094

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- If the pressure now no longer falls, replace the EVAP canister purge regulator valve 1.

If the pressure still decreases, perform the "Fuel System Leak Test". Refer to FUEL SYSTEM LEAK TEST .