Transfer Fuel Pump -G6-, CHECKING, 4-CYLINDER TFSI VEHICLES

Special tools and workshop equipment required

Injection Rate Comparison Meter Kit - Remote Cable: VAG1348/3A with Injection Rate Kit - Remote Cable: VAG1348/3-3

Fig 1: Identifying Remote Control Connection V.A.G 1348/3A
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Analog/Digital Multimeter : FLU83III

Fig 2: Analog/Digital Multimeter FLU83III
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Connector Test Set: VAG1594D
Pressure Tester Kit: VAS6550 with Pressure Tester Kit - Hose 1: VAS6550/1 and : VAS6550/2

Fig 3: Identifying Pressure Tester Kit VAS 6550
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Pressure Tester Kit - Regulator Valve: VAS6550/4

Fig 4: Identifying Pressure Regulator Valve VAS 6550/4
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Scraper no. 1 from the Scraper Set: VAS6845

Fig 5: Identifying Clip release lever no. 4 from the Scraper Set VAS6845
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Fuel-Resistant Measuring Container

A - Checking Fuel Delivery Rate

Fig 6: The Fuel Filler Cap

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

-- Open the fuel filler door.

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

-- Move the front seats all the way forward into the highest position.

FWD Vehicles:

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

-- Remove the luggage compartment floor.

-- Remove the storage compartment for the vehicle tool kit.

-- Q3 Sportback: pull and disengage and remove the cover -3- for the left support upward in direction of -arrow A-.

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-- Remove the bolts -2- for the left support -1- and disengage the carrier upward in direction of -arrow B- and remove.

-- Remove the button -2-.

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-- Disengage the trim -1- under the C-pillar trim panel and remove it in direction of -arrows-.

-- Fold the trim over the sealing flange cover toward the right to the side.

-- Unclip the sealing flange cover -1- with the scraper from the : VAS6845 at the frame in direction of -arrows-.

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

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

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

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

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

AWD Vehicles:

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

-- Remove the luggage compartment floor.

-- Remove the storage compartment for the vehicle tool kit.

-- Q3 Sportback: pull and disengage and remove the cover -1- for the right support upward in direction of -arrow A-.

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-- Remove the bolts -2- for the right support -3- and disengage the carrier upward in direction of -arrow B- and remove.

-- Remove the button -1-.

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-- Disengage the trim -2- from under the C-pillar trim panel and remove in direction of -arrows-.

-- Fold the trim over the sealing flange cover toward the left to the side.

-- Unclip the right sealing flange cover -1- with the scraper from the : VAS6845 at the frame -arrows-.

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-- Unlock the connector safety catch and disconnect the connector -3- on the right sealing flange.

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-- 2. Tape off the second connector terminal of the Injection Rate Kit - Remote Cable: 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 Connector Test Set: VAG1594D .

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

Continuation for All Vehicles:

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

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

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-- Attach the Pressure Tester Kit - Regulator Valve: VAS6550/4 .

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

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

Fig 7: Identifying Shut-Off Valves A And B On Pressure Tester Kit

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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: VAS6550/4 as follows:

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

The levers point in the flow direction.

-- Press the remote control switch.

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

Fig 8: Identifying Pressure Regulator Valve Adjusting Screw

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Specified value: 4.0 bar (58.02 psi) pressure.

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

-- Empty the measuring container.

-- Press the remote control switch for 15 seconds to initiate the measurement.

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

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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.

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 9: 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.
Injection Rate Comparison Meter Kit - Remote Cable: VAG1348/3A still connected.

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

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

The levers point in 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 Pressure Tester Kit: VAS6550 :

Specified value: minimum 6.0 bar (87.02 psi)

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 Pressure Tester Kit: VAS6550 :

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 (43.51 psi):

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.
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 10: 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.

-- 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.

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

Tightening Specifications

Refer to OVERVIEW - LUGGAGE COMPARTMENT SIDE TRIM PANEL .