Transfer Fuel Pump -G6-, CHECKING, VEHICLES WITH 4-CYLINDER ENGINE

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

Special tools and workshop equipment required

Injection Rate Comparison Meter Kit - Remote Cable: VAG1348/3A with Injection Rate Kit - Remote Cable: VAG1348/3-3
Analog/Digital Multimeter : FLU83III
Connector Test Set: VAG1594D
Pressure Tester Kit: VAS6550 with Pressure Tester Kit - Hose 1: VAS6550/1 and : VAS6550/2
Pressure Regulator Valve: VAS6550/4
Fuel-Resistant Measuring Container
Emergency refueling funnel from the vehicle tool kit

A - Checking fuel delivery rate

-- Observe all test conditions. Refer to TEST CONDITIONS .

-- Move the front seats all the way forward.

-- Switch off the ignition.

-- Open the fuel filler door.

-- Insert the emergency refueling funnel -1- from the vehicle tool kit all the way into the filler neck -arrow-.

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TT Coupe:

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

TT Roadster:

-- Remove the right rear panel trim panel. Refer to REAR PANEL TRIM PANEL, REMOVING AND INSTALLING .

-- Remove the right rear panel. Refer to the appropriate Service Information.

Continuation for All Vehicles:

Fig 1: Fuel Pump Cover (Under Rear/Bench Seat)

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-- Unclip the right sealing flange cover -1- at the tabs -arrows- using the : 3409 .

FWD Vehicles:

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-- Release the connector safety catch, and disconnect the connector -1- on the sealing flange.

-- Connect the : VAG1348/3A to the contact -1- using the : VAG1348/3-3 and cable from the : VAG1594D .

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-- 2. Tape off the second connector terminal of the : VAG1348/3-3 with insulating tape -arrow- to prevent short circuits.

-- Connect the contact -5- to the body ground -A- using an adapter cable from the : VAG1594D .

-- Connect the alligator clip to battery "+" -item B-.

AWD Vehicles:

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-- Release the connector safety catch to disconnect the connector -1- on the right sealing flange.

-- Connect the : VAG1348/3A to the contact -1- using the : VAG1348/3-3 and cable from the : VAG1594D .

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-- 2. Tape off the second connector terminal of the : VAG1348/3-3 with insulating tape -arrow- to prevent short circuits.

-- Connect the connector terminal -2- to the body ground -A- with an adapter cable from the : VAG1594D .

-- Connect the alligator clip to battery "+" -item B-.

Continuation for All Vehicles:

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WARNING:

Risk of injury due to the fuel being under high pressure.

To reduce the pressure in the fuel system, lay clean cloths around the connection point and carefully loosen the connection point.

-- Disconnect the fuel line -1-. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

-- Connect the : VAS6550 to the fuel supply line with the : VAS6550/2 .

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-- Attach the : VAS6550/4 and hold the hose in a fuel-resistant measuring container.

-- Switch on the : VAS6550 -item 1- by pressing the On/Off button.

Fig 2: Identifying Shut-Off Valves A And B On Pressure Tester Kit

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NOTE:

To measure the fuel delivery rate, an initial pressure must be created in the fuel line which the fuel pump must work against during measurement. The initial pressure is adjusted using the : VAS6550/4 as follows:

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

The levers point in the flow direction.

CAUTION:

Risk of fuel leaking.

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

-- Press the remote control switch.

-- To generate the initial pressure in the fuel system, turn the adjusting screw -1- on the : VAS6550/4 until the correct initial pressure value is reached.

Fig 3: Identifying Pressure Regulator Valve Adjusting Screw

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Specified value: 4.0 bar pressure.

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

-- Empty the measuring container.

-- Press the remote control switch for 15 seconds.

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

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NOTE:

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

If the minimum delivery rate is attained:

The fuel delivery unit and the fuel supply line are OK.

If the minimum delivery rate is not obtained, it may be due to the following malfunctions:

Fuel delivery unit faulty.
Fuel supply line is crushed.

NOTE:

To more accurately locate the malfunction, perform the "pressure test in the fuel supply line" described in the following.

B - Pressure test in the fuel supply line

Fig 4: Identifying Shut-Off Valves A And B On Pressure Tester Kit

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Set up the equipment as if measuring for the fuel delivery rate.
: VAG1348/3A still connected.

-- Switch on the : VAS6550 -item 1- by pressing the On/Off button.

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

The levers point in the flow direction.

CAUTION:

Risk of fuel leaking.

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

-- Press the remote control switch.

-- If the fuel flows without bubbles, close the shut-off valve -B- so that the fuel pressure increases.

The lever is perpendicular to the flow direction.

-- Read the fuel pressure on the : VAS6550 :

Specified value: minimum 6.0 bar

If the specified value is obtained, even though the fuel delivery rate was not OK:

The fuel delivery unit integrated fuel filter is blocked or the fuel supply line is crushed.

If the specified value is not attained:

Fuel delivery unit faulty.

C - Checking residual pressure

-- Check the residual pressure and also for leaks by monitoring the decrease in pressure on the : VAS6550 :

There still must be a pressure of at least 3 bar after 10 minutes.

If the residual pressure drops below 3 bar:

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

Assembling

Assemble in the reverse order of removal. Note the following:

The ignition must be off.

NOTE:

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

Fig 5: Identifying Shut-Off Valves A And B On Pressure Tester Kit

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-- Remove the : VAS6550 with the connecting lines.

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

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

TT Coupe:

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

TT Roadster:

-- Install the right rear panel. Refer to the appropriate Service Information.

-- Install the right rear panel trim panel. Refer to REAR PANEL TRIM PANEL, REMOVING AND INSTALLING .