Retrofitting fuel cut-off valve control unit J366 — VW

Retrofitting fuel cut-off valve control unit
J366
Note
When retrofitting the vehicle diagnosis, testing and information system
VAS 5051 A or vehicle diagnosis and service information system
VAS 5052 are required.
Before starting retrofitting, check whether the fuel shut-off valve
N109 wiring harness contains a 2-pin connector. It is also possible to check if the immobilizer is fitted with vehicle diagnosis, testing and information system
VAS 5051 A or vehicle diagnosis and service information system
VAS 5052 via address word 25
“Immobilizer”.
In vehicles without a 2-pin connector, retrofitting the control unit for a fuel shut-off valve is not possible.
The retrofit set
“control unit for fuel shut-off valve” is made up of:
M5 hexagon nut
Item
Clamp
Item
Lower part of cover cap
Item
Upper part of cover cap
Item
Fuel shut-off valve control unit
J366
Item
Shear bolt and Grease (blister packing)
Item
Retrofitting fuel cut-off valve control unit
J366:
Unscrew hexagon bolt and washer assemblies and hexagon nuts (arrows)
, release locking lever, swing down noise insulation tray and unhook at brackets.
Unscrew left and right securing bolts (1).
Fold out radiator and lock carrier (arrow).
Switch off ignition.
Remove injector lines as a complete set
Diesel direct fuel injection and glow plug system
Rep. Gr.
23.
Note
No fuel must spill on hoses or lines!
Disconnect 2-pin connector for the fuel shut-off valve
Current flow diagrams, Electrical fault finding and Fitting locations.
Disconnect and remove line at fuel shut-off valve.
The removed line is no longer needed.
Grease semi-circular surface of clamp (2) with provided grease.
Insert clamp (2) behind fuel shut-off valve
N109 (1).
Also grease the clamping surfaces with provided grease on fuel shut-off valve control unit
J366.
Screwed connection surfaces and threaded holes must be free of grease!
Using hexagon nut (1)
, firmly screw cover cap lower part (4) and single cable (2) of the fuel shut-off valve control unit (1) to fuel shut-off valve
N109 (3)
, 1.5 Nm +1 Nm.
After screwing, the terminal must have the position shown in the figure.
Slide cover cap upper part (2) as shown over hexagon nut onto cover cap lower part (1) and snap in.
Slide fuel shut-off valve control unit
J366 (1) onto fuel shut-off valve
N109 (A) until control unit lies against valve.
The single line (X) must not be pinched.
At first only hand-tighten securing bolts (shear bolts) (1) so that the bolt heads do not break off.
Note
Once the bolt heads are sheared off the securing bolts cannot be unscrewed again! The securing bolts must therefore be finally tightened only after the immobilizer is functionally checked.
Re-install injector lines as a complete set
Diesel direct fuel injection and glow plug system
Rep. Gr.
23.
Connect 2-pin connector from fuel cut-off valve control unit to open connector (see current flow diagram).
Secure line as with previous line.
Adapting fuel shut-off valve control unit
J366 to immobilizer control unit
J362:
Note
In the delivered condition the fuel shut-off valve control unit always switches on the fuel shut-off valve, even when not enabled by the immobilizer control unit.
The fuel shut-off valve control unit
J366 must be adapted to the immobilizer control unit
J362 to ensure correct functioning of the immobilizer.
Adapt fuel shut-off valve control unit
J366 to the immobilizer control unit
J362
Electrical system, self-diagnosis
Rep. Gr.
01
Guided functions for immobilizer; Adaption after changing engine control unit.
Carrying out functional check of immobilizer:
Start engine and let run at least 10 seconds.
Interrogate fault memory
Electrical system, self-diagnosis
Rep. Gr.
01
Immobilizer self-diagnosis; Performing immobilizer self-diagnosis; Interrogating fault memory.
If a fault is detected:
Remove fault using fault table
Electrical system, self-diagnosis
Rep. Gr.
01
Immobilizer self-diagnosis; Fault table.
Delete fault memory
Electrical system, self-diagnosis
Rep. Gr.
01
Immobilizer self-diagnosis; Performing immobilizer self-diagnosis; Deleting fault memory.
Interrogate fault memory again
Electrical system, self-diagnosis
Rep. Gr.
01
Immobilizer self-diagnosis; Performing immobilizer self-diagnosis; Interrogating fault memory.
If no fault is detected:
Alternately tighten securing bolts (shear bolts) (1) until bolt heads break off. This operation is easiest when performed from the underside of the vehicle.
Install engine compartment cover (noise insulation):
When installing tighten bolts and nuts to 9 Nm.
Fit radiator and lock carrier again.
Enter retrofitting in service schedule with the following text:
“S085 (date/stamp)”