Transfer Fuel Pump -G6-, CHECKING (A5/S5/RS5 THROUGH MY 2011, A4/S4 THROUGH MY 2012)

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Special tools and workshop equipment required

Injection Rate Comparison Meter Kit - Remote Cable VAG 1348/3A with Injection Rate Kit - Remote Cable VAG 1348/3-3.
Fuel Injection Gauge Kit - 12 VAG1318/12 for S5 8-Cylinder
Fuel Injection Gauge Kit - Adapter Set VAG1318/17A for S5 8-Cylinder
Connector Test Set VAG1594D
Pressure Tester Kit VAS6550 with hose lines VAS6550/1 and VAS6550/2
Pressure Regulator Valve VAS6550/4
Measuring container, fuel-resistant

A - Check Fuel Delivery Rate

Fig 1: Identifying Cover Bolts For Locking Flange

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-- Follow all test requirements. Refer to TEST CONDITIONS .

-- Remove the rear bench seat. Refer to SEAT BENCH/SINGLE SEAT, REMOVING AND INSTALLING .

-- Remove the locking flange cover -arrows-.

-- Disconnect the connector -1- on the sealing flange.

Fig 2: Disconnect Connectors

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NOTE:

Ignore item -2-.

-- Push the circlip -1- upward in direction of -arrow A- and squeeze the release in direction of -arrow B-.

Fig 3: Pulling Lock -1- Upward -Arrow A- & Press -Arrow B-

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-- Connect the Injection Rate Comparison Meter Kit - Remote Cable VAG1348/3A using the remote cable VAG1348/3-3 and cable from the Connector Test Set VAG1594D to the terminal -1-.

Fig 4: Checking Fuel Pressure

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-- Tape the second Injection Rate Kit - Remote Cable VAG1348/3-3 with insulating tape -arrow-.

-- Connect the connector terminal -5- to the body ground with an adapter cable from the Connector Test Set VAG1594D.

-- Place the switch for the Injection Rate Comparison Meter Kit - Remote Cable VAG1348/3A toward front in engine compartment.

-- Remove the center plenum chamber cover. Refer to PLENUM CHAMBER COVER, REMOVING AND INSTALLING .

Fig 5: Identifying Cover, Removal

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-- Releases the retainer in direction of -arrow A- and open the cover in direction of -arrow B-.

Fig 6: Opening Terminal Box Cover

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-- Connect the alligator clip to the Battery Jump Start Terminal -U6- -A- in the Terminal 30 Wire Junction 2 -TV22- in the plenum chamber.

Fig 7: Checking Fuel Pressure

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-- Release and open the fuel filler door.

Fig 8: Identifying Cap -2-

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-- Remove the cap -2- for the fuel filler -1-.

NOTE:

Ignore item -3-.

WARNING:

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

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

Vehicles with 4-Cylinder Engines

Fig 9: Identifying Fuel Line

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-- Disconnect the fuel line -2-. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, SEPARATING .

Vehicles with 6-Cylinder FSI and TFSI Engines

Fig 10: Locating Fuel Line -1-

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-- Loosen the clamp and remove the fuel line -1-.

-- Connect the Pressure Tester Kit - Hose 1 VAS6550/1 and adapter hose -1- to the fuel supply line and secure them with hose clamps -2-.

Fig 11: Connecting Fuel Supply Line To Test Kit Adapter Hose

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S5 with 8-Cylinder Engine

Fig 12: Identifying Engine Cover

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-- Remove the engine cover in direction of -arrows-.

-- Disconnect the fuel line -arrow-.

Fig 13: Disconnecting Fuel Line

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-- Connect the Fuel Injection Gauge Kit - Adapter Set VAG1318/17A using the Fuel Injection Gauge Kit - Adapter 12 VAG1318/12 to the fuel line -1-.

Fig 14: Connecting Fuel Injection Gauge Kit - Adapter Set VAG1318/17A

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RS5

Fig 15: Identifying Engine Cover

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-- Remove the engine cover in direction of -arrows-.

-- Fold the boot -1- downward and disconnect the hose coupling -2-. Refer to CONNECTOR COUPLINGS, SEPARATING .

Fig 16: Pushing Hose Coupling -2- Downward -Arrow A-, Then Press Release Buttons -Arrow B-

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Continuation for All Vehicles

Fig 17: Identifying Diesel Pressure Tester Kit VAS 6550 With Diesel Pressure Tester Kit - Hose 2 VAS 6550/2

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-- Connect the Diesel Pressure Tester Kit VAS6550 with the Diesel Pressure Tester Kit - Hose 2 VAS6550/2 to the fuel supply line.

-- Connect the Pressure Regulator Valve VAS6550/4 and hold the hose in a fuel-resistant measuring container.

NOTE:

The illustration shows the measuring setup for a 4-cylinder engine.

-- Turn the Pressure Tester Kit VAS6550 -1- on by pressing the On/Off button.

Fig 18: Identifying Shut-Off Valves A And B On Pressure Tester Kit

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-- Open the shut-off valves -A and B-.

The levers point in the direction of flow.

CAUTION:

Risk of fuel leak.

The shut-off valve -C- must be closed.
The lever is perpendicular to the direction of flow.

NOTE:

In order to measure the fuel delivery rate, there must be an initial pressure inside the fuel line against which the fuel pump must work during the measuring. Adjust the initial pressure using the Pressure Tester Kit VAS6550 as follows:

-- Push the remote control switch: the fuel pump starts running.

-- Turn the adjusting screw -1- on the Pressure Regulator Valve VAS6550/4 to create an initial pressure in the fuel system until the correct initial pressure value is reached.

Fig 19: Identifying Pressure Regulator Valve Adjusting Screw

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Specified value: 4 bar (58 psi) pressure.

-- Release the remote control switch.

-- Do not turn the adjusting screw -1- any farther.

-- Empty measuring container.

-- Press the remote control switch for 15 seconds.

Fig 20: Compare Quantity Of Fuel Delivered With Minimum Delivery Rate In Diagram

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

NOTE:

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

If the Minimum Delivery Rate Is Attained

Due to the engine design and the fuel supply pump installed in the fuel tank, do not bleed the fuel system.

If Minimum Delivery Quantity Is Not Obtained, the Following Malfunctions May Be Present

Fuel delivery unit faulty.
The fuel filter is clogged.
The fuel pressure regulator is faulty.
Fuel supply line is pinched.

NOTE:

To locate the fault in more detail, perform the "pressure test in the fuel supply line", described as follows.

B - Pressure Test in the Fuel Supply Line

Fig 21: Identifying Shut-Off Valves A And B On Pressure Tester Kit

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Connect the measuring setup as if measuring the delivery quantity.

-- Turn the Pressure Tester Kit VAS6550 -1- on by pressing the On/Off button.

-- Open the shut-off valves -A and B-.

The levers point in the direction of flow.

CAUTION:

Risk of fuel leak.

The shut-off valve -C- must be closed.
The lever is perpendicular to the direction of flow.

-- Push the remote control switch: the fuel pump starts running.

-- If the fuel flows without bubbles, close the drain -B-, so that the fuel pressure increases.

The lever is perpendicular to the direction of flow.

-- Read the fuel pressure in the Pressure Tester Kit VAS6550:

Specified value: 5.0 to 8.0 bar (72.5 to 116 psi)

If Specified Value Is Obtained, Although the Fuel Delivery Unit Is Not OK

The fuel filter is clogged or the fuel supply line is kinked

If the Specification Is Not Attained

Fuel delivery unit or fuel pressure regulator (on the fuel filter) is faulty.

C - Checking Residual Pressure

-- Watch the pressure fall on the Pressure Tester Kit VAS6550 while checking the holding pressure and checking for leaks:

After 10 minutes there must be a residual pressure of at least 3 bar (43 psi).

If the Residual Pressure Drops Below 3 bar (43 psi)

Check fuel lines and their connections for leaks.
The fuel pump check valve in the fuel pump leaks: replace the fuel delivery unit. Refer to FUEL DELIVERY UNIT/FUEL LEVEL SENSOR, REMOVING AND INSTALLING .

Assembling

Assembly is performed in the reverse order of disassembly, noting the following:

The ignition must be off.

-- Remove the remote control.

NOTE:

Decrease the fuel pressure by opening the drains -B and C- and letting the fuel run into the measuring container before removing the pressure gauge -1-.

Fig 22: Identifying Shut-Off Valves A And B On Pressure Tester Kit

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-- Remove the Pressure Tester Kit VAS6550 with the connecting lines.

-- Connect the fuel supply line:

Vehicles with 6-Cylinder FSI and TFSI Engines

-- Secure the fuel supply line with a clamp and then pull on it to make sure it is secure.

Vehicles with 4-Cylinder Engines and RS5

-- Attach the fuel supply line so that it clicks into place.

-- Press the fuel supply line on again and pull to make sure the connector coupling is engaged correctly.

S5 with 8-Cylinder Engine

-- Secure the fuel line on the fuel rail. Refer to OVERVIEW - FUEL INJECTION SYSTEM for 3.2L, engine code CALA .

Continuation for All Vehicles

-- Install the sealing flange cover. Refer to Figure.

-- Install the rear bench seat. Refer to SEAT BENCH/SINGLE SEAT, REMOVING AND INSTALLING .