Transfer Fuel Pump - G6- /Fuel Pump - G23-, CHECKING, VEHICLES WITH 3.0L (V6)/4.2L (V8) ENGINE THROUGH 05/2010

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Special tools and workshop equipment required

Injection Rate Comparison Meter Kit - Remote CableVAG1348/3A with Injection Rate Kit - Remote Cable VAG1348/3-3.
Measuring container, fuel-resistant

Procedure

Fig 1: Identifying Left Plenum Chamber Cover -1- Above E-Box

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Follow all test requirements, refer to TEST CONDITIONS .

Follow the guidelines for clean working conditions, refer to CLEAN WORKING CONDITIONS .

-- Remove the cap from the fuel filler tube.

-- Open the left plenum chamber cover -1- above the E-box.

-- Turn the quick-release fasteners -1, 3 and 4- counter-clockwise 90° in direction of -arrows-.

Fig 2: Turning Quick-Release Fasteners -1, 3 And 4- Counter-Clockwise 90Degrees -Arrows- To Remove Relay/Fuse Holder Cover -2-

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-- Remove the relay/fuse holder cover -2-.

-- Remove the fuses for both fuel pumps in the relay/fuse holder in the E-box on the left side of the plenum chamber, refer to the appropriate Wiring Diagram.

Fig 3: Locating Relay And Fuse Carrier In Left E-Box Plenum Chamber

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-- Connect the Injection Rate Comparison Meter Kit - Remote Cable VAG1348/3A with Injection Rate Kit - Remote Cable VAG1348/3-3 to the left terminal -arrow 1- and -arrow 2- for the socket for both fuel pump fuses, refer to the appropriate Wiring Diagram.

Fig 4: VAG1348/3-3

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NOTE:

Vehicles from 09/2008 with engine codes CCMA, CATA, from 06/2009 CCFA.

Fig 5: Identifying 2nd Connector -Arrow 2- Of V.A.G 1348/3-3, V.A.G 1348/3A, V.A.G 1348/3-3, And Left Terminal -Arrow 1-

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Connect the Injection Rate Comparison Meter Kit - Remote Cable VAG1348/3A with the Injection Rate Kit - Remote CableInjection Rate Kit - Remote Cable VAG1348/3-3 to the left terminal -arrow 1- in the socket for the fuel pump fuse. Refer to the appropriate Wiring Diagram.

Using insulating tape, tape over the second connector terminal -arrow 2- of the Injection Rate Kit - Remote Cable Injection Rate Kit - Remote Cable VAG1348/3-3 to prevent a short circuit.

NOTE:

Place a clean cloth under the separating location to catch any fuel that may leak out.

Fig 6: Identifying Fuel Filter, Fuel Hoses -1 Through 4-, Bolts -5 & 7-, And Nut -6-

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WARNING:

Very hot fuel can burn your skin.

In extreme cases, the fuel lines and the fuel itself in vehicles with a common rail engine can be as hot as 100 °C (212 °F) after the engine has been turned off. Let the fuel cool down before opening any line connections otherwise there is a danger of scalding.
Wear safety gloves
Wear protective eyewear.

There is a risk of injury because the fuel is under pressure.

To reduce pressure in fuel system, lay a clean cloth around the connector and carefully loosen connector.

CAUTION:

Always observe the rules for cleanliness when working on the injection system, refer to CLEAN WORKING CONDITIONS .

-- Remove the fuel supply hose -1- from the fuel filter.

NOTE:

Ignore the other items.

-- Hold the remove fuel supply hose -arrow- in a measuring container.

Fig 7: Holding Remove Fuel Supply Hose -Arrow- In Measuring Container

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NOTE:

Attach an extension hose to the fuel supply hose if necessary.

-- Press and hold the switch on the remote control for 15 seconds.

Fig 8: Identifying Fuel Delivery Rate Diagram

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-- Compare quantity of fuel delivered with minimum delivery rate in diagram (cm³ /15s).

NOTE:

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

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

The fuel tank does not have enough fuel in it.
The fuel lines are pinched.
One of the two fuel pumps is faulty.

NOTE:

This test does not test the throughput of the fuel filter. Test the filter separately, if necessary.