paramedick
TDIClub Enthusiast, Vendor
"I grabbed the green handle. All diesel fuel handles are green, right?" Around here, diesel fuel pumps can have green, black, or yellow handles. You filled up your car with gasoline..
Hopefully you realized it before you started the car, or shut if off when it started running roughly. In any case, do not restart the car. Trailer it to wherever you need to to repair the car.
We all know how critical lubricity is to the HPFP in the CBEA cars. Gasoline has no lubricity value. Your fuel system may already be damaged. You may experience a future HPFP failure. Please, no comments here about future failures.
Fuel system must be completely purged of contaminated fuel. This how-to will show you the easiest method to accomplish this.
Disclaimer. This was my experience. Your experience may differ. I can take no responsibility for your work or results.
Assuming you are removing gasoline from the car, be aware of the ability of gasoline to generate fumes easily. Work in a well-ventilated area. No open flames. I suggest using worklights that won't generate a spark if bulb is broken. Clean any spills immediately, and put fuel-soaked materials outside. Dispose of waste fuel in a responsible manner.
Tools/materials needed
Mityvac, preferably with large collection bottle
cable operated hose clamp pliers
T30 torx driver
small hammer
brass drift
6 foot of 1/4 inch fuel line
5/16 inch brass barbed connector
4 x 5 gallon containers for contaminated fuel
1) remove the T30 torx screws x 5 that secure the lid to the fuel filter cannister. Secure the lid out of the way with a zip tie to the fuel lines. Remove contaminated fuel filter and set aside. Using mityvac, remove fuel from fuel filter cannister. Use a lint-free absorbent material to dry out cannister. Examine material, fuel, and fuel filter for metal sparklies. If you see sparklies, your HPFP has already been damaged. Take the car somewhere for further repairs. Alternate method: Remove fuel cannister from car to clean if that is your desire.
2) reinstall fuel filter cannister lid loosely with 2-3 screws to provide a stable work surface for next steps.
3) remove the fuel line from the fuel tank to the cannister lid. Picture below shows which line. Cable operated clamp pliers work great, regular pliers not so well due to new clamp design. Connect fuel line to 1/4 inch fuel line with the brass barbed fitting. Route to container for contaminated fuel.
4) Connect VCDS. Turn ignition on. Select 01 engine and open field. Click on basic settings. Enter 035 in left most window and select that field. Click the "on/off button" at top of VCDS window. Lift pump will begin to operate. Allow it to run until it is no longer pumping fuel to waste fuel container, about 1 minute. Allow lift pump to rest 2-3 minutes and repeat above. Three cycles of lift pump will substantially fill a 5 gallon container. When container is filled, put cap on it and set outside for safety. Swap in new container. If tank is full, it will take 4 containers.
5) When fuel is no longer being pumped from the 1/4 inch hose to waste fuel container, click the "on/off" button again to shut off lift pump. Turn off ignition. Leave hose connected to tank line and run to waste fuel container.
6) Remove back seat. Peel back carpeting that covers fuel tank sender/lift pump and secure out of the way by method of your choice. Remove wiring boot from plastic cover. Lift up plastic cover (no screws, friction fit). Unplug wiring from lift pump and remove plastic cover. Move wiring out of the way.
7) Clean top of sending unit/lift pump. It will be quite dirty.
8) Release two fuel lines from the sending unit. There is a release clip you push to do so. Remember where they go. Move fuel lines out of the way the best you can.
9) Use a permanent marker to make orientation marks between the fuel tank opening, retaining ring, and sending unit. Do this in several places. There is a quality control sticker that may be present that can act as one orientation mark.
10) Retaining ring is metal with notches at regular intervals. The notches mate with bent tabs on fuel tank opening. Take your brass drift and hammer, and tap the retaining ring counter-clockwise until it releases. Picture above shows ring/tab relationship when it is released. Remove retaining ring and set aside.
11) Lift up on sender unit/lift pump and remove slowly. Remember to tilt it to clear the fuel level float. Remove from car. There is fuel in the sender unit, so spread some absorbent materials to catch drippage, and have something to set the sender unit on to remove from car. Empty all fuel from the sender unit. Clean as necessary. Set aside in safe place.
12) You will have less than one gallon of fuel left in tank. It has to come out. Choose your favorite lint-free absorbent material and start soaking up the fuel. Reach into the tank and make sure you clean out all the nooks and crannies. Hint, Pig brand absorbent pads do a great job in absorbing the fuel (available at NAPA and other FLAPS).
13) Ensure that the rubber gasket that seals the sender unit in place is in correct postion. It it inserted into the tank opening, and it's "U" shaped design is retained both above and below the opening. You can see gasket in above image.
14) Insert sender unit/lift pump into tank opening. Remember, you have to tilt it to clear the float arm. Set retaining ring in position, noting your reference marks. Push down on the fuel sender to seat it, and turn retaining ring slightly to engage the tabs. Use your brass drift to tap it clockwise to align your reference marks. Plug fuel lines back onto proper nipples. Insert wiring connector thru plastic cover and reconnect to sender unit. Secure plastic cover in place. Secure wiring boot to plastic cover.
15) Reinstall seat
16) Add fresh diesel fuel to fuel tank. At least 5 gallons so lift pump doesn't have to work so hard. I suggest 8-10 gallons. Add some type of lubricity additive to the fuel. 1 quart of B100 would be perfect. I used 16 ounces of Stanadyne.
17) Using VCDS procedure above, purge fuel lines of contaminated fuel into waste container. Hit stop button when you get pure diesel fuel. You will notice a color change.
18) Remove barbed fitting from tank fuel line, and secure it to the fuel filter lid and clamp it.
19) Install new fuel filter and gaskets. Vent fuel filter cannister as described above, using new vent screw seal that came with the fuel filter
20) Secure lid on fuel filter cannister. Remove vent screw from fuel filter cannister lid. Use VCDS procedure to fill fuel filter until fuel is expelled from vent. Replace vent screw.
21) Remove fuel return line from fuel filter. Connect 1/4 inch fuel line to nipple on the fuel cannister lid. Route to waste container. Using VCDS procedure above, purge the fuel system of contaminated fuel and air. You will need to run the lift pump at least one full cycle to purge the fuel system and the fuel filter cannister of any contaminated fuel. Remove 1/4 inch hose, and reinstall return line onto fuel filter cannister lid. Put clamp back in place.
22) Remove fuel filter cannister lid. Remove fuel and examine for metal sparklies.
23) Start the car. It may take 10-15 seconds of cranking to remove gasoline from fuel injectors. Car will start roughly, and smooth out within 5-10 seconds. Let idle 1-2 minutes. You might get a stumble if there are any air bubbles.
24) Using VCDS, clear any codes. You will have a code for the fuel level sender, and multiple cylinder misfire codes if car was run with gasoline.
25) Test drive 10-15 miles. Car should run smoothly without stumbling.
Hopefully you realized it before you started the car, or shut if off when it started running roughly. In any case, do not restart the car. Trailer it to wherever you need to to repair the car.
We all know how critical lubricity is to the HPFP in the CBEA cars. Gasoline has no lubricity value. Your fuel system may already be damaged. You may experience a future HPFP failure. Please, no comments here about future failures.
Fuel system must be completely purged of contaminated fuel. This how-to will show you the easiest method to accomplish this.
Disclaimer. This was my experience. Your experience may differ. I can take no responsibility for your work or results.
Assuming you are removing gasoline from the car, be aware of the ability of gasoline to generate fumes easily. Work in a well-ventilated area. No open flames. I suggest using worklights that won't generate a spark if bulb is broken. Clean any spills immediately, and put fuel-soaked materials outside. Dispose of waste fuel in a responsible manner.
Tools/materials needed
Mityvac, preferably with large collection bottle
cable operated hose clamp pliers
T30 torx driver
small hammer
brass drift
6 foot of 1/4 inch fuel line
5/16 inch brass barbed connector
4 x 5 gallon containers for contaminated fuel
1) remove the T30 torx screws x 5 that secure the lid to the fuel filter cannister. Secure the lid out of the way with a zip tie to the fuel lines. Remove contaminated fuel filter and set aside. Using mityvac, remove fuel from fuel filter cannister. Use a lint-free absorbent material to dry out cannister. Examine material, fuel, and fuel filter for metal sparklies. If you see sparklies, your HPFP has already been damaged. Take the car somewhere for further repairs. Alternate method: Remove fuel cannister from car to clean if that is your desire.
2) reinstall fuel filter cannister lid loosely with 2-3 screws to provide a stable work surface for next steps.
3) remove the fuel line from the fuel tank to the cannister lid. Picture below shows which line. Cable operated clamp pliers work great, regular pliers not so well due to new clamp design. Connect fuel line to 1/4 inch fuel line with the brass barbed fitting. Route to container for contaminated fuel.
4) Connect VCDS. Turn ignition on. Select 01 engine and open field. Click on basic settings. Enter 035 in left most window and select that field. Click the "on/off button" at top of VCDS window. Lift pump will begin to operate. Allow it to run until it is no longer pumping fuel to waste fuel container, about 1 minute. Allow lift pump to rest 2-3 minutes and repeat above. Three cycles of lift pump will substantially fill a 5 gallon container. When container is filled, put cap on it and set outside for safety. Swap in new container. If tank is full, it will take 4 containers.
5) When fuel is no longer being pumped from the 1/4 inch hose to waste fuel container, click the "on/off" button again to shut off lift pump. Turn off ignition. Leave hose connected to tank line and run to waste fuel container.
6) Remove back seat. Peel back carpeting that covers fuel tank sender/lift pump and secure out of the way by method of your choice. Remove wiring boot from plastic cover. Lift up plastic cover (no screws, friction fit). Unplug wiring from lift pump and remove plastic cover. Move wiring out of the way.
7) Clean top of sending unit/lift pump. It will be quite dirty.
8) Release two fuel lines from the sending unit. There is a release clip you push to do so. Remember where they go. Move fuel lines out of the way the best you can.
9) Use a permanent marker to make orientation marks between the fuel tank opening, retaining ring, and sending unit. Do this in several places. There is a quality control sticker that may be present that can act as one orientation mark.
10) Retaining ring is metal with notches at regular intervals. The notches mate with bent tabs on fuel tank opening. Take your brass drift and hammer, and tap the retaining ring counter-clockwise until it releases. Picture above shows ring/tab relationship when it is released. Remove retaining ring and set aside.
11) Lift up on sender unit/lift pump and remove slowly. Remember to tilt it to clear the fuel level float. Remove from car. There is fuel in the sender unit, so spread some absorbent materials to catch drippage, and have something to set the sender unit on to remove from car. Empty all fuel from the sender unit. Clean as necessary. Set aside in safe place.
12) You will have less than one gallon of fuel left in tank. It has to come out. Choose your favorite lint-free absorbent material and start soaking up the fuel. Reach into the tank and make sure you clean out all the nooks and crannies. Hint, Pig brand absorbent pads do a great job in absorbing the fuel (available at NAPA and other FLAPS).
13) Ensure that the rubber gasket that seals the sender unit in place is in correct postion. It it inserted into the tank opening, and it's "U" shaped design is retained both above and below the opening. You can see gasket in above image.
14) Insert sender unit/lift pump into tank opening. Remember, you have to tilt it to clear the float arm. Set retaining ring in position, noting your reference marks. Push down on the fuel sender to seat it, and turn retaining ring slightly to engage the tabs. Use your brass drift to tap it clockwise to align your reference marks. Plug fuel lines back onto proper nipples. Insert wiring connector thru plastic cover and reconnect to sender unit. Secure plastic cover in place. Secure wiring boot to plastic cover.
15) Reinstall seat
16) Add fresh diesel fuel to fuel tank. At least 5 gallons so lift pump doesn't have to work so hard. I suggest 8-10 gallons. Add some type of lubricity additive to the fuel. 1 quart of B100 would be perfect. I used 16 ounces of Stanadyne.
17) Using VCDS procedure above, purge fuel lines of contaminated fuel into waste container. Hit stop button when you get pure diesel fuel. You will notice a color change.
18) Remove barbed fitting from tank fuel line, and secure it to the fuel filter lid and clamp it.
19) Install new fuel filter and gaskets. Vent fuel filter cannister as described above, using new vent screw seal that came with the fuel filter
20) Secure lid on fuel filter cannister. Remove vent screw from fuel filter cannister lid. Use VCDS procedure to fill fuel filter until fuel is expelled from vent. Replace vent screw.
21) Remove fuel return line from fuel filter. Connect 1/4 inch fuel line to nipple on the fuel cannister lid. Route to waste container. Using VCDS procedure above, purge the fuel system of contaminated fuel and air. You will need to run the lift pump at least one full cycle to purge the fuel system and the fuel filter cannister of any contaminated fuel. Remove 1/4 inch hose, and reinstall return line onto fuel filter cannister lid. Put clamp back in place.
22) Remove fuel filter cannister lid. Remove fuel and examine for metal sparklies.
23) Start the car. It may take 10-15 seconds of cranking to remove gasoline from fuel injectors. Car will start roughly, and smooth out within 5-10 seconds. Let idle 1-2 minutes. You might get a stumble if there are any air bubbles.
24) Using VCDS, clear any codes. You will have a code for the fuel level sender, and multiple cylinder misfire codes if car was run with gasoline.
25) Test drive 10-15 miles. Car should run smoothly without stumbling.
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