Fuel pump (vehicles with 8-cyl. FSI engine), checking delivery rate

Special tools, testers and auxiliary items required

Fig 1: Identifying Pressure Gauge V.A.G 1318

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pressure gauge K-Jetronic V.A.G 1318
Pressure gauge adapter V.A.G 1318/10-12

Fig 2: Identifying Remote Control Connection V.A.G 1348/3A

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Remote Control V.A.G 1348/3A with adapter cable V.A.G 1348/3-3
Measuring container, fuel-resistant

Fig 3: Identifying Fuel Pump (FP) Control Module J538

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Work procedure

Battery voltage min. 12.5 V.
Fuel Pump (FP) Control Module J538 OK; check in "Guided Fault Finding" with Vehicle Diagnosis, Testing and Information System VAS 5051.
Fuel filter OK.
Fuel tank at least ¹ /₄ filled.

Ignition switched off.

CAUTION: Observe safety precautions → Safety precautions .

Fig 4: Removing Cover Of Right Luggage Compartment Side Trim

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Remove cover of right luggage compartment side trim - arrows -.

Fig 5: Removing Cover Above Battery

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Remove cover - 2 - above battery.

NOTE:

Ignore - 1 -.

Remove trim for luggage compartment floor.

Fig 6: Removing/Installing Cover For Left Locking Flange

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Remove cover for left locking flange - arrows -.

Fig 7: Disconnecting/Connecting Electrical Connectors At Left Locking Flange

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Disconnect electrical harness connector - 2 - at left locking flange.

NOTE:

Ignore - 1 -.

Fig 8: Removing/Installing Cover For Right Locking Flange

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Remove cover for right locking flange - arrows -.

Fig 9: Disconnecting Electrical Harness Connector At Right Locking Flange

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Disconnect electrical harness connector - 2 - at right locking flange.

NOTE:

Ignore - 1 -.

Fig 10: Connecting Remote Control For Vag 1348 V.A.G 1348/3A With Adapter Cable V.A.G 1348/3-3 And Adapter Cables From Connector Test Set V.A.G 1594C To Terminal (Ground) On Left/Right Delivery Unit

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Connect Remote Control for VAG 1348 V.A.G 1348/3A with adapter cable V.A.G 1348/3-3 and adapter cables from Connector Test Set V.A.G 1594C to terminal - 4 - (ground) on left and right delivery unit.
Route Remote Control V.A.G 1348/3A switch forward in engine compartment.
Connect alligator clip to Ground (GND) point in engine compartment.
Connect terminal - 1 - (positive) on left and right delivery unit using a self-made adapter cable to battery "+". For safety reasons, install a fuse - A - (10 A) in wiring.

Remove fuel filler cap from fuel filler tube.

Fig 11: Removing Rear Engine Cover

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Pull rear engine cover - arrows - off.

CAUTION: Fuel system is under pressure! Before opening system, place clean rags around the connection. Then release pressure by carefully loosening the connection.

Fig 12: Disconnecting Fuel Supply Line On Distribution Piece

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Disconnect fuel supply line - arrow - on distribution piece.

CAUTION: Note rules of cleanliness for working on fuel injection system → Rules for cleanliness .

Disconnect fuel line - arrow -.

Fig 13: Connecting Fuel Inj. Pressure Gauge-CIS V.A.G 1318 With Adapter V.A.G 1318/11 And V.A.G 1318/12 In Fuel Line

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Connect Fuel Inj. Pressure Gauge-CIS V.A.G 1318 with Adapter V.A.G 1318/11 and V.A.G 1318/12 in fuel line.
Connect assisting hose - arrow - on pressure gauge and hold it in a measuring container.
Open shut-off valve of pressure gauge set. The lever points in direction of flow.
Generate pressure in fuel system by pressing switch of remote control and slowly closing shut-off valve of pressure gauge.

Specified value: 4 bar positive pressure.

From this point on do not move position of shut-off tap.
Empty measuring container.
Press switch on remote control for 15 seconds.

Fig 14: Identifying Fuel Delivery Graph

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Compare quantity of fuel delivered with minimum delivery rate in diagram (cm ³ /15s).

NOTE:

Voltage at fuel pump with engine stopped and pump running is approx. 2 volts less than battery voltage.

If minimum delivery quantity is not obtained, the following malfunctions may be present:

Fuel lines pinched.
Fuel filter clogged.
Fuel pump faulty.

NOTE:

Because the quantity of fuel delivered does not decrease significantly when one of the fuel pumps malfunctions - due to the internal lines in the tank - a faulty pump cannot be diagnosed accurately by measuring the quantity delivered.

In this case, proceed as follows:

Remove electrical adapter cable at each fuel delivery unit.
Measure quantity delivered at opposite fuel delivery unit.

If quantity delivered by individually measured fuel delivery unit is considerably less than specified value:

Replace affected fuel delivery unit.

Assembly is in reverse order of removal, note the following:

Attach fuel line to engine →
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