Fuel System - Crank, No Start After Long Periods Without Drivin
20 12 04December 5, 2012
2031557
Vehicle Information
Condition
Crank, No Start after Long Periods without Driving
Note:
This concern usually happens with dealer owned vehicles typically during PDI.
Faults may or may not be present.
Technical Background
The black in-tank fuel lines contain a material known as PA12. PA12 was not meant to be used with fuel containing alcohol/methanol/ethanol. If PA12 fuel lines sit in fuel for over 3 day without driving and in
temperatures over 77 F (25 C) a chemical reaction occurs that creates small white crystals to form on the lines (figure 1). These crystals can flake off into the fuel, gumming up the pumps and lines.
Note:
A reaction of the in-tank fuel line exterior will only occur one time, once the material has been removed, the lines and system require no further repairs.
Production Solution
Fuel lines made without PA12 to be placed into production.
Implementation date open at the time of publishing.
Service
Procedure
^ Check for debris in the fuel system, and if present, follow the steps below for cleaning the fuel system.
Note:
A reaction of the in-tank fuel line exterior will only occur one time, once the material has been removed, the lines and system require no further repairs.
^ Remove engine cover.
WARNING:
^ Remove the fuel supply line to the high pressure pump (figure 2).
^ Place the fuel supply line into a fuel safe clear container (figure 3) and cycle the key for 2 seconds 2 times.
^ Check the sample of fuel for debris.
^ If debris is found (figure 4), remove the rear seat bottom to gain access to the in-tank fuel pump.
^ If no debris is found (figure 4), please contact the Volkswagen Technician Helpline for further instructions.
Note:
If the fuel tank is full, remove some fuel through the filler neck before removing the pump to prevent fuel from overflowing into the vehicle.
^ Remove the in-tank fuel pump and recover as much of the contaminated fuel as possible using an approved
gas caddy.
^ Once the fuel tank is empty, reinstall the in-tank fuel pump, rear seat bottom and fill the tank with $20.00 of new fuel.
^ With new fuel in the tank, reinsert the supply line into a fuel safe clear container and cycle the key for 2
seconds 5 times (figure 5). This is done to clean out the fuel line with new fuel.
^ Before reinstalling the fuel supply line onto the high pressure pump, use brake cleaner and shop rag to flush out the high pressure pump inlet (figure 6). Spray brake cleaner into inlet using a 1 second burst (you may have to repeat this step 2-3 times to ensure all debris is removed).
Tip:
Figure 6 shows the placement of the brake cleaner nozzle to the high pressure pump. Figure 7 shows the placement of the shop rag and the removed debris, some pumps may contain more/less debris.
Make sure the shop rag is wrapped around the inlet/spray nozzle before spraying the brake cleaner
^ Using GFF clear faults if present.
^ If the crank no start condition persists after this procedure has been performed, please contact the Volkswagen Technician Helpline for further instructions.
Warranty
Required Parts and Tools
No special parts required.
No special tools required.
Additional Information
All part and service references provided in this Technical Bulletin are subject to change and/or removal.
Always check with your Parts Dept. and Repair Manuals for the latest information.