Transfer Fuel Pump -G6-, CHECKING, 3-CYLINDER AND 4-CYLINDER TFSI VEHICLES

WARNING: This page is about a different car, the 2023 Audi S3, 2023 Audi RS 3, 2023 Audi A3 Quattro, and 2023 Audi A3. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Injection Rate Comparison Meter Kit - Remote Cable:VAG 1348/3A with Injection Rate Kit - Remote Cable:VAG 1348/3-3

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Analog/Digital Multimeter:FLU83III

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Connector Test Set:V.A.G 1594D

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Pressure Tester Kit:VAS 6550 with Pressure Tester Kit - Hose 1:VAS 6550/1

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Pressure Regulator Valve:VAS 6550/4

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Fuel-Resistant Measuring Container

A - Checking Fuel Delivery Rate

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

-- Open the fuel filler door.

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

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

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

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

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FWD Vehicles:

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

-- Connect the Injection Rate Comparison Meter Kit - Remote Cable:V.A.G 1348/3A to the contact -1- using the Injection Rate Kit - Remote Cable :V.A.G 1348/3-3 and cable from the Connector Test Set:V.A.G 1594D .

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-- 2. Tape off the second connector terminal of the Injection Rate Kit - Remote Cable :V.A.G 1348/3-3 with insulating tape -arrow- to prevent short circuits.

-- Connect the contact -5- to the body ground -A- using an adapter cable from the Connector Test Set:V.A.G 1594D .

-- 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.

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-- 2. Tape off the second connector terminal of the Injection Rate Kit - Remote Cable :V.A.G 1348/3-3 with insulating tape -arrow- to prevent short circuits.

-- Connect the connector terminal -2- to the chassis ground -A- with an adapter cable from the Connector Test Set:V.A.G 1594D .

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

Continuation:

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

CAUTION:

The fuel system is under pressure.

Risk of injury from fuel spraying out.

- Wear protective eyewear.

- Wear safety gloves.

- Reduce the pressure: place clean cloths around the connection point and carefully open the connection point.

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

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-- 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.

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-- Turn on the Pressure Tester Kit:VAS 6550 -item 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:VAS 6550/4 as follows:

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

The levers point in the flow direction.

-- Close the shut-off valve -C-.

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 Pressure Tester Kit - Regulator Valve:VAS 6550/4 until the correct initial pressure value is reached.

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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 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

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Set up the equipment as if measuring for the fuel delivery rate.
Injection Rate Comparison Meter Kit - Remote Cable:V.A.G 1348/3A still connected.

-- Turn 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.

-- Close the shut-off valve -C-.

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 Pressure Tester Kit:VAS 6550 :

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 Pressure Tester Kit:VAS 6550 :

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.
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-.

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

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