Volkswagen CJDA Workshop Manual page 400

3
Industriemotoren - Industrial Engines 2009 ▶
Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015
Caution
After installation, the high pressure pump must be filled
with fuel before the engine is started the 1st time (the pump
must NOT be allowed to run while still empty).
Note
◆ When installing the high-pressure pump, it is essential to en-
sure that no dirt enters the fuel system.
◆ Only remove sealing plugs immediately prior to installation of
fuel lines.
◆ The fuel tank must be filled.
Proceed as follows to fill high-pressure pump with fuel:
– Switch on ignition.
– Connect vehicle diagnostic tester, and select engine control
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unit.
– Perform final control diagnosis, and activate fuel pump for
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120 seconds
Note
◆ The fuel pump must be activated for at least 180 seconds.
Since the activation of the fuel pump is limited to 120 sec-
onds, the final control diagnosis must be performed twice.
◆ To allow for performing the final control diagnosis a second
time, switch off ignition, and switch it back on.
– Perform final control diagnosis again, and activate fuel pump
for 120 seconds.
– Then start engine.
– After filling fuel system, leave engine running at moderate
speed for a few minutes and then switch off again.
– Check fuel system for leaks.
– Then, read event memory of engine control unit, and clear
event memory if necessary
– Perform a road test/test run, accelerating to full throttle at
least once. Check high pressure part of fuel system again for
leaks.
Note
If there is any air left in the fuel system, the engine may switch
to the limp mode during the road test/test run. Switch off the en-
gine and clear the event memory. Then, continue road test/test
run.
– Finally, read event memory of engine control unit again
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26, read event memory.
1.16 Checking fuel system for leaks
– Clean re-installed fuel connections with brake cleaner and
then dry them.
384 Repair Group 23 - Mixture preparation - injection
89, final control diagnosis.
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26, read event memory.