Transfer Fuel Pump -G6-, CHECKING, TFSI VEHICLES

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Special tools and workshop equipment required

Pressure Tester Kit:VAS 6550 with Pressure Tester Kit - Hose 2:VAS 6550/2

Fig 1: Identifying Pressure Tester Kit VAS 6550
Courtesy of AUDI
Pressure Tester Kit - Adapter Set:VAS 6550/3

Fig 2: Identifying Pressure Tester Kit - Adapter Set VAS 6550/3
Courtesy of AUDI
Pressure Tester Kit - Regulator Valve:VAS 6550/4

Fig 3: Identifying Pressure Regulator Valve VAS 6550/4
Courtesy of AUDI
Vehicle Diagnostic Tester
Fuel-Resistant Measuring Container

A - Checking fuel delivery rate

Fig 4: The Fuel Filler Cap

Courtesy of AUDI

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

-- Open the fuel filler door.

-- Remove the fuel filler neck cap -arrow-.

-- Remove the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING - 2.0L DMSA , ENGINE COVER, REMOVING AND INSTALLING - 2.0L DPVA , ENGINE COVER - 3.0L .

2.0L TFSI Vehicles:

Courtesy of AUDI

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

-- Connect the Pressure Tester Kit:VAS 6550 to the fuel supply hose using the Pressure Tester Kit - Hose 2:VAS 6550/2 .

Courtesy of AUDI

-- Attach the Pressure Tester Kit - Regulator Valve:VAS 6550/4 .

-- Hold the hose in a fuel-resistant measuring container and secure the measuring container. A second technician may be required.

3.0L TFSI Vehicles:

Courtesy of AUDI

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

-- Connect the Pressure Tester Kit:VAS 6550 to the fuel supply line with the Pressure Tester Kit - Hose 2:VAS 6550/2 .

Courtesy of AUDI

-- Attach the Pressure Tester Kit - Regulator Valve:VAS 6550/4 .

-- Hold the hose in a fuel-resistant measuring container and secure the measuring container. A second technician may be required.

Continuation for All Vehicles:

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

Courtesy of AUDI

-- Switch on the Pressure Tester Kit:VAS 6550 -item 1- by pressing the On/Off button.

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 Pressure Tester Kit - Regulator Valve:VAS 6550/4 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.

-- Connect the Vehicle Diagnostic Tester.

-- Switch the ignition on.

-- Select the OBD mode.

Select 0001 - engine electronics .
Select basic setting in the control module basic setting menu item.
Select Draining fuel tank from the list.

-- Press Start .

The fuel pump starts.

-- To generate the initial pressure in the fuel system, turn the adjusting screw -1- on the Pressure Tester Kit - Regulator Valve:VAS 6550/4 until the correct initial pressure value is reached.

Fig 6: Identifying Pressure Regulator Valve Adjusting Screw

Courtesy of AUDI

Specified value: 4.5 bar (65.27 psi) pressure.

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

-- Press the Stop button.

-- Empty the measuring container.

-- To measure, press the Start button again and let the fuel pump run for 15 seconds.

-- After 15 seconds, press the Stop button.

-- Check the fuel delivery rate in the measuring container.

2.0L specified value: minimum delivery rate 400 cm³ /15 s.
3.0L specified value: minimum delivery rate 700 cm³ /15 s.

If the minimum delivery rate is attained:

The fuel delivery unit with the fuel filter, fuel pressure regulator and fuel supply line are OK.

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

Fuel delivery unit with integrated fuel filter is faulty.
Fuel pressure regulator in the fuel delivery unit is 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 7: Identifying Shut-Off Valves A And B On Pressure Tester Kit

Courtesy of AUDI

Set up the equipment as if measuring for the fuel delivery rate.
Vehicle Diagnostic Tester is still connected.

-- Switch on the Pressure Tester Kit:VAS 6550 -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 Start on the Vehicle Diagnostic Tester display: the fuel pump starts running.

-- 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 Pressure Tester Kit:VAS 6550 :

Specified value: 6.0 to 8.0 bar (87.02 to 116.03 psi).

-- Press the Stop button.

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

Fuel filter in the fuel delivery unit is plugged or the fuel supply line is crushed.

If the specified value is not attained:

Fuel delivery unit or fuel pressure regulator in the fuel tank is faulty.

C - Checking residual pressure

-- Check the residual pressure and also for leaks by monitoring the decrease in pressure on the Pressure Tester Kit:VAS 6550 :

There still must be a pressure of at least 3 bar (43.51 psi) 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, TDI VEHICLES .

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 allowing the fuel drain into the measuring container before removing the pressure tester -1-.

Fig 8: Identifying Shut-Off Valves A And B On Pressure Tester Kit

Courtesy of AUDI

-- Remove the Pressure Tester Kit:VAS 6550 with the connecting lines.

-- Connect the fuel hose with the connector coupling. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

-- Install the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING - 2.0L DMSA , ENGINE COVER, REMOVING AND INSTALLING - 2.0L DPVA , ENGINE COVER - 3.0L .