Fuel Pump Delivery Rate, Checking

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Fuel Inj. Pressure Gauge-CIS VAG 1318
Adapter VAG 1318/11
Adapter VAG 1318/17A
Fuel Line Feed Adapter VAG 1318/23
Remote Control VAG 1348/3A with Remote Control for VAG1348 VAG 1348/3-3
Connector Test Set VAG 1594C
Measuring container, fuel-resistant

Procedure

Fig 1: Identifying Fuel Pump (FP) Control Module J538

Courtesy of AUDI OF AMERICA, LLC

Fuse for Fuel Pump Control Module -J538- OK, refer to the appropriate Wiring Diagram.
Battery voltage at least 12.5 V.
FP control module OK; check in Guided Fault Finding using a vehicle diagnostic tester.
Fuel filter OK.
Fuel tank minimum ¹ /₄ full.
Ignition turned off

NOTE:

The Fuel Pump Control Module -J538- is located on the right side under the rear seat bench, directly under the floor covering.

-- Remove right seat frame in 2nd row. Refer to SECOND ROW, 2 PASSENGER OVERVIEW .

Fig 2: Cut Floor Covering Along Perforation

Courtesy of AUDI OF AMERICA, LLC

WARNING:

Risk of injury.

Wear safety gloves.

-- Cut the floor covering along the perforation -arrows- on the right side with a carpet knife -1-.

-- Press the floor covering to the side and disconnect the connector -1-.

Fig 3: Fuel Pump (FP) Control Module -J538- And Fasteners (For Vehicles From 11.2006)

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Ignore the -arrows-.

All Vehicles:

Fig 4: Identifying Connector Terminals -1 & 2-, VAG 1594C Cable, Chassis Ground (-), VAG 1348/3A With VAG 1348/3-3, And Cover -A-

Courtesy of AUDI OF AMERICA, LLC

-- Connect connector terminal -2- with an adapter cable from Connector Test Set VAG 1594C to chassis Ground (GND).

-- Connect Remote Control VAG 1348/3A with Remote Control for VAG1348 VAG 1348/3-3 to terminal -1- on connector.

-- Cover the second connector terminal of Remote Control for VAG1348 VAG 1348/3-3 with insulating tape to prevent short circuit -arrow-.

-- Route Remote Control VAG 1348/3A switch forward in the engine compartment.

-- Release the retaining clip and open the cover -A- over the positive terminal clamp.

-- Connect the alligator clip to the positive terminal clamp.

-- Remove the fuel cap from the fuel filler tube.

WARNING:

Risk of injury from fuel.

Before opening the fuel system, lay a clean cloth around the connection point and carefully loosen it, which lowers the pressure.

-- Fold the boot -1- to the side and disconnect the fuel line.

Fig 5: Pushing Hose Coupling -2- On Fuel Line -Arrow A- And Then Pressing Release Buttons -Arrows B-

Courtesy of AUDI OF AMERICA, LLC

-- Push the hose coupling -2- in direction of -arrow A-, then press the release buttons -arrow B-.

-- Remove the hose coupling with the release buttons pressed.

-- Connect the Fuel Line Feed Adapter VAG 1318/23 and Adapter VAG 1318/17-1A to the Fuel Inj. Pressure Gauge-CIS VAG 1318.

Fig 6: Identifying VAG 1318/23, VAG 1318/17-1A, VAG 1318, VAG 1318/11, Assisting Hose -Arrow-, And Measuring Container

Courtesy of AUDI OF AMERICA, LLC

-- Adapter VAG 1318/17-1A installed on the removed fuel line.

-- Connect the Adapter VAG 1318/11 to the Fuel Inj. Pressure Gauge-CIS VAG 1318.

-- Push an assisting hose -arrow- onto it and hold it into a measuring container.

-- Open the pressure gauge shut-off valve.

The lever points in the direction of flow.

-- Bleed fuel system by briefly pressing remote control.

-- Generate pressure in the fuel system by pressing the switch of the remote control and slowly closing the shut-off valve of the pressure gauge.

Specified value: 4 bar positive pressure.

-- From this point on do not move position of shut-off valve.

-- Empty the measuring container.

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

Fig 7: Delivery Rate Diagram

Courtesy of AUDI OF AMERICA, LLC

-- 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:

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

Assembling

Fig 8: Identifying VAG 1318/23, VAG 1318/17-1A, VAG 1318, VAG 1318/11, Assisting Hose -Arrow-, And Measuring Container

Courtesy of AUDI OF AMERICA, LLC

Assemble in reverse order of disassembling. Note the following:

NOTE:

Before disconnecting pressure gauge, release pressure by opening shut-off valve. Hold the hose in a measuring container -arrow-.

-- Connect the fuel supply line 1. Check for cleanliness and leaks.

-- Install the frame into the floor covering. Refer to FRONT FLOOR COVERING, REMOVING AND INSTALLING .

-- Install right seat frame in 2nd row. Refer to SECOND ROW, 2 PASSENGER OVERVIEW .

Special tools and workshop equipment required

Fuel Inj. Pressure Gauge-CIS VAG 1318
Adapters VAG 1318/10-12
Remote Control VAG 1348/3A with Remote Control for VAG1348 VAG 1348/3-3
Connector Test Set VAG 1594C
Measuring container, fuel-resistant

Procedure

Fig 1: Identifying Fuel Pump (FP) Control Module J538

Courtesy of AUDI OF AMERICA, LLC

Fuse for Fuel Pump Control Module -J538- OK, refer to the appropriate Wiring Diagram.
Battery voltage at least 12.5 V.
FP control module OK; check in Guided Fault Finding using a vehicle diagnostic tester.
Fuel filter OK.
Fuel tank minimum ¹ /₄ full.
Ignition switched off

Vehicles through October 2006:

Fig 2: Identifying Fuel Pump (FP) Control Module, Bolts -1 & 3-, And Electrical Connector -2-

Courtesy of AUDI OF AMERICA, LLC

NOTE:

FP control module is located at front of fuel tank below exhaust system and driveshaft.

WARNING:

Danger of getting burned.

Allow exhaust system to cool.

-- Disconnect electrical connector -2-.

NOTE:

Ignore -1 and 3- and -arrow-.

Vehicles from November 2006:

NOTE:

The FP control module is located on the right side under the rear seat bench, directly under the floor covering.

-- Remove right seat frame in 2nd row. Refer to SECOND ROW, 2 PASSENGER OVERVIEW .

Fig 3: Cut Floor Covering Along Perforation

Courtesy of AUDI OF AMERICA, LLC

WARNING:

Risk of injury.

Wear safety gloves.

-- Cut the floor covering along the perforation -arrows- on the right side with a carpet knife -1-.

-- Press the floor covering to the side and disconnect the connector -1-.

Fig 4: Fuel Pump (FP) Control Module -J538- And Fasteners (For Vehicles From 11.2006)

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Ignore -arrows-.

All Vehicles:

Fig 5: Identifying Connector Terminals -1 & 2-, VAG 1594C Cable, Chassis Ground (-), VAG 1348/3A With VAG 1348/3-3, And Cover -A-

Courtesy of AUDI OF AMERICA, LLC

-- Connect connector terminal -2- with an adapter cable from Connector Test Set VAG 1594C to chassis Ground (GND).

-- Connect Remote Control VAG 1348/3A with Remote Control for VAG1348 VAG 1348/3-3 to terminal -1- on connector.

-- Cover the second connector terminal of the Remote Control for VAG1348 VAG 1348/3-3 with insulating tape to prevent short circuit -arrow-.

-- Route the Remote Control VAG 1348/3A switch forward in engine compartment.

-- Release the retaining clip and open the cover -A- over the positive terminal clamp.

-- Connect the alligator clip to the positive terminal clamp.

-- Remove the fuel cap from the fuel filler tube.

WARNING:

Risk of injury from fuel.

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

-- Disconnect fuel line -2-.

Fig 6: Identifying Electrical Harness Connector -1-

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Ignore -1-.

-- Connect Fuel Inj. Pressure Gauge-CIS VAG 1318 with Adapter VAG 1318/11 and Adapter VAG 1318/12 in fuel line.

Fig 7: Connecting VAG 1318 With VAG 1318/11 And VAG 1318/12 In Fuel Line

Courtesy of AUDI OF AMERICA, LLC

-- Connect assisting hose -arrow- on pressure gauge and hold it in a measuring container.

-- Open shut-off valve of pressure gauge.

The lever points in the direction of flow.

-- Generate pressure in the fuel system by pressing the switch of the remote control and slowly closing the shut-off valve of the pressure gauge.

Specified value: 4 bar positive pressure.

-- From this point on do not move position of shut-off valve.

-- Empty the measuring container.

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

Fig 8: Delivery Rate Diagram

Courtesy of AUDI OF AMERICA, LLC

-- 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:

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

Assemble in reverse order of disassembling. Note the following:

-- Attach fuel line to engine. Refer to Description and Operation .

Vehicles from November 2006:

-- Install the frame into the floor covering. Refer to FRONT FLOOR COVERING, REMOVING AND INSTALLING .

-- Install right seat frame in 2nd row. Refer to SECOND ROW, 2 PASSENGER OVERVIEW .

Special tools and workshop equipment required

Fuel Inj. Pressure Gauge-CIS VAG 1318
Adapter VAG 1318/10
Adapter VAG 1318/11
Remote Control VAG 1348/3A with Remote Control for VAG1348, VAG 1348/3-3
Connector Test Set VAG 1594C
Measuring container, fuel-resistant

Procedure

Fig 1: Identifying Fuel Pump (FP) Control Module J538

Courtesy of AUDI OF AMERICA, LLC

Fuse for Fuel Pump Control Module -J538- OK, refer to the appropriate Wiring Diagram.
Battery voltage at least 12.5 V.
FP control module OK; check in Guided Fault Finding using a vehicle diagnostic tester.
Fuel filter OK.
Fuel tank minimum ¹ /₄ full.
Ignition switched off

Vehicles through October 2006:

Fig 2: Identifying Fuel Pump (FP) Control Module, Bolts -1 & 3-, And Electrical Connector -2-

Courtesy of AUDI OF AMERICA, LLC

NOTE:

FP control module is located at front of fuel tank below exhaust system and driveshaft.

WARNING:

Danger of getting burned.

Allow exhaust system to cool.

-- Disconnect electrical connector -2-.

NOTE:

Ignore -1 and 3- and -arrow-.

Vehicles from November 2006:

NOTE:

The FP control module is located on the right side under the rear seat bench, directly under the floor covering.

-- Remove right seat frame in 2nd row. Refer to SECOND ROW, 2 PASSENGER OVERVIEW .

Fig 3: Cut Floor Covering Along Perforation

Courtesy of AUDI OF AMERICA, LLC

WARNING:

Risk of injury.

Wear safety gloves.

-- Cut the floor covering along the perforation -arrows- on the right side with a carpet knife -1-.

-- Press the floor covering to the side and disconnect the connector -1-.

Fig 4: Fuel Pump (FP) Control Module -J538- And Fasteners (For Vehicles From 11.2006)

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Ignore -arrows-.

All Vehicles:

Fig 5: Identifying Connector Terminals -1 & 2-, VAG 1594C Cable, Chassis Ground (-), VAG 1348/3A With VAG 1348/3-3, And Cover -A-

Courtesy of AUDI OF AMERICA, LLC

-- Connect connector terminal -2- with an adapter cable from Connector Test Set VAG 1594C to chassis Ground (GND).

-- Connect Remote Control VAG 1348/3A with Remote Control for VAG1348 VAG 1348/3-3 to terminal -1- on connector.

-- Cover the second connector terminal of Remote Control for VAG1348 VAG 1348/3-3 with insulating tape to prevent short circuit -arrow-.

-- Route Remote Control VAG 1348/3A switch forward in the engine compartment.

-- Release the retaining clip and open the cover -A- over the positive terminal clamp.

-- Connect the alligator clip to the positive terminal clamp.

-- Remove the fuel cap from the fuel filler tube.

-- Pull the rear engine cover off -arrows-.

Fig 6: Removing Rear Engine Cover

Courtesy of AUDI OF AMERICA, LLC

WARNING:

Risk of injury from fuel.

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

-- Disconnect fuel supply line -3- and the distribution piece.

Fig 7: Identifying Vacuum Hose To Evaporative Emission (EVAP) Canister Purge Regulator Valve N80

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Ignore -1 and 2-.

-- Connect Fuel Inj. Pressure Gauge-CIS VAG 1318 with Adapter VAG 1318/10 and Adapter VAG 1318/11 in fuel line.

Fig 8: Connecting Fuel Pressure Gauge-CIS VAG 1318

Courtesy of AUDI OF AMERICA, LLC

-- Connect an assisting hose -arrow- to pressure gauge and hold it in a measuring container.

-- Open shut-off valve of pressure gauge.

The lever points in the direction of flow.

-- Generate pressure in the fuel system by pressing the switch of the remote control and slowly closing the shut-off valve of the pressure gauge.

Specified value: 4 bar positive pressure.

-- From this point on do not move position of shut-off valve.

-- Empty the measuring container.

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

Fig 9: Delivery Rate Diagram

Courtesy of AUDI OF AMERICA, LLC

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

NOTE:

Voltage at the 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:

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

Assemble in reverse order of disassembling. Note the following:

NOTE:

Secure all hose connections with hose clamps of the same type as those equipped by the factory. .

Vehicles from November 2006:

-- Install the frame into the floor covering. Refer to FRONT FLOOR COVERING, REMOVING AND INSTALLING .

-- Install right seat frame in 2nd row. Refer to SECOND ROW, 2 PASSENGER OVERVIEW .