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

Special tools and workshop equipment required 

• Vehicle Diagnostic Tester
• Pressure Tester Kit:VAS6550  with Pressure Tester Kit - Hose 2:VAS6550/2 
  Fig 1: Identifying Pressure Tester Kit VAS 6550

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• Pressure Tester Kit - Adapter Set:VAS6550/3 
  Fig 2: Identifying Pressure Tester Kit - Adapter Set VAS 6550/3

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

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• Measuring container that contains at least 2.5 liters, fuel-resistant
• A7 Sportback: emergency refueling funnel from the vehicle tool kit

A - Checking Fuel Delivery Rate

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

-- Open the fuel filler door.

-- A6: remove the fuel filler neck cap -arrow-.

-- A7 Sportback: insert the emergency refueling funnel -1- from the vehicle tool kit all the way into the filler neck in direction of -arrow-.

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-- Remove the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

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

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-- Connect the Pressure Tester Kit:VAS6550  to the fuel supply hose using the Pressure Tester Kit - Hose 2:VAS6550/2  .

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-- Attach the Pressure Tester Kit - Regulator Valve:VAS6550/4  and hold the hose in a fuel-resistant measuring container.

-- 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.

• 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.

-- Check if the shut-off valve -C- is closed.

• The lever is perpendicular to the flow direction.

-- Connect the Vehicle Diagnostic Tester.

-- Switch the ignition on.

-- Select Diagnostic  and start.

• 0001 - Engine electronics J623 
• 0001 - basic setting 
• 0001 - Drain fuel tank 

-- 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:VAS6550/4  until the correct initial pressure value is reached.

• 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.

• Specified value: minimum delivery rate 800 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.

TIP:

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

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

-- Check if the shut-off valve -C- is 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:VAS6550  :

• 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: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:

• Check the fuel lines and their connections for leaks.
• The check valve in the fuel pump leaks: replace the fuel delivery unit. Refer to appropriate Service Information .

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 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

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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.