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HOMESERVICE MANUALSVOLKSWAGEN2002GOLF GLS, 2.0 K, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 94 (2.8L - ENGINE MECHANICAL, ENGINE CODE: BDF)26 - EXHAUST SYSTEM, EMISSION CONTROLSSECONDARY AIR SYSTEMEVAP SYSTEM, CHECKING USING KLI 9210 TESTERCHECKING EVAP SYSTEM FOR LEAKS
2002 Volkswagen Golf GLS, 2.0 K, Standard

Checking EVAP system for leaks

2002 Volkswagen Golf GLS, 2.0 K, StandardSECTION Checking EVAP system for leaks
WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2005 Volkswagen GTI, 2004 Volkswagen Jetta, 2004 Volkswagen GTI, 2003 Volkswagen Jetta, and 2003 Volkswagen GTI. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Locating LDP Outlet (EVAP Side)
GW00000875Courtesy of VOLKSWAGEN UNITED STATES, INC.
  • Clamp off LDP outlet (EVAP side) - 1  - using special tool Hose Clamps Up to 25mm dia. 3094 or equivalent.
CAUTION: Clamp only soft rubber lines when isolating a leak. To avoid risk of damage, never clamp hard plastic lines!
  • Turn control valve from "Hold" to "Test".
  • Allow fuel system to pressurize.
NOTE:
  • Fuel system pressurization depends on volume of fuel system and amount of fuel in tank.

If fuel system pressurization does not stabilize:

  • Verify that all fuel system outlets have been sealed before continuing.
NOTE:
  • Any flow shown on flow meter indicates a leak. Flow below flow meter flag set at vehicle leak standard may indicate a sporadic DTC.

If flow meter on tester registers flow near or above pre-set pressure:

  • Clamp off hose leading from EVAP canister purge regulator valve N80 to intake manifold.

If flow stops:

  • Replace EVAP canister purge regulator valve N80 and repeat test before continuing.

If meter indicates no flow after test:

  • Perform quality check and return vehicle to customer.

If flow continues:

  • Use smoke generator trigger to charge fuel system with smoke again.
  • Inspect complete EVAP system for escaping smoke.
NOTE:
  • It may be necessary to move, twist, or wiggle EVAP components around to reproduce leak.

If leak cannot be found using smoke:

Fig 2: Ultrasonic Tester
GW00000876Courtesy of VOLKSWAGEN UNITED STATES, INC.
  • Locate leak with ultrasonic tester.
  • General search: tester only
  • Localized search: tester with extension wand (left)

If leak cannot be located:

  • Disconnect and plug or clamp shut EVAP lines to isolate fuel tank using special tool Hose Clamps Up to 25mm dia. 3094 or equivalent before continuing.
CAUTION: Clamp only soft rubber lines when isolating a leak. To avoid risk of damage, never clamp hard plastic lines!

If flow stops:

  • Reconnect EVAP lines and search area that was isolated.

When leak has been located:

  • Repair leak and repeat EVAP system test.
NOTE:
  • Because leak may be at top of fuel tank, it may not be possible to locate through fuel pump/sending unit access plate.
  • Lower fuel tank if necessary to locate leak.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.