Fuel Pressure And Residual Pressure, Checking, Vehicles With 3.2L FSI Engine

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Special tools and workshop equipment required

Injection Rate Comparison Meter Kit - Remote Cable VAG1348/3A with Injection Rate Kit - Remote Cable VAG1348/3-3.
Connector Test Set VAG1594D
Pressure Tester Kit VAS6550 with hose lines Pressure Tester Kit - Hose 1 VAS6550/1 and Pressure Tester Kit - Hose 2 VAS6550/2
Measuring container, fuel-resistant

Procedure

Fig 1: Identifying Locking Flange Cover & Bolts -Arrows-

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-- Follow all test requirements, refer to TEST CONDITIONS .

-- Remove 1/3 of the rear seat, refer to REAR SEAT, REMOVING AND INSTALLING .

-- Remove the bolts -arrows- and remove the sealing flange cover -1-.

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

Fig 2: Identifying Connector -1- On Locking Flange

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-- 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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-- Press on the marked location in direction of -arrow A- and remove the cover -2-.

Fig 4: Pressing On Marked Location -Arrow A- & Remove Cover -2-

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-- Release the latch in direction of -arrow B- and open the cover -1-.

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

Fig 5: Connecting - VAG 1348/3A- Using - VAG 1348/3-3- & Cable From - VAG 1594C- To Terminal -1-

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

-- Connect the connector terminal -5- to the chassis 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.

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

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.

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

Fig 6: Locating Fuel Line -1-

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-- 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 7: Connecting Fuel Supply Line To Test Kit Adapter Hose

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-- Connect the Pressure Tester Kit - Hose 1 VAS6550/1 to the Pressure Tester Kit VAS6550.

Fig 8: Holding Test Kit Adapter Hose Into Fuel-Resistant Measuring Container

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-- Connect the Pressure Tester Kit - Hose 2 VAS6550/2 and hold the hose in a fuel-resistant measuring container.

Fig 9: Identifying Pressure Tester VAS 6550 And Shut-Off Valve -B- (Closed)

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CAUTION:

Risk of fuel leak.

Make sure that the drain -C- is closed.
The lever is perpendicular to the direction of flow.

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

The levers point in the direction of flow.

-- Press the button of the remote control.

-- 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 to 6.5 bar (65 to 94 psi)

If the specification is not attained:

-- Fuel pump, checking fuel delivery quantity, refer to FUEL, CHECKING DELIVERY QUANTITY, VEHICLES WITH 3.2L FSI ENGINE .

Residual Pressure, Checking

-- 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 the connection between the Pressure Tester Kit VAS6550 and the fuel supply line for leaks.
Checking the Pressure Tester Kit VAS6550 for leaks.
Check fuel lines and their connections for leaks.

If no faults are detected:

Replace the locking flange with the fuel filter and fuel pressure regulator, refer to FUEL FILTER, REMOVING AND INSTALLING .

-- Repeat the residual pressure check.

If there are still 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 .

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

The ignition must be off.

NOTE:

Open the shut-off valve -B- and drain valve -C- and let the fuel drain into the measuring container before removing the pressure gauge for the fuel pressure.

Fig 10: Identifying Pressure Tester VAS 6550 And Shut-Off Valve -B- (Closed)

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-- Remove the Pressure Tester Kit VAS6550 with hose lines Pressure Tester Kit - Hose 1 VAS6550/1 and Pressure Tester Kit - Hose 2 VAS6550/2

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