Transfer Fuel Pump -G6-, CHECKING, 5-CYLINDER TFSI VEHICLES

Special tools and workshop equipment required 

• Pressure Tester Kit:VAS 6550  with Pressure Tester Kit - Hose 1:VAS 6550/1  and :VAS 6550/2 

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• Pressure Regulator Valve:VAS 6550/4 

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• Vehicle Diagnostic Tester
• A measuring container that holds at least 3 liters and is fuel resistant (commercially available)
• Emergency refueling funnel from the vehicle tool kit

A - Checking Fuel Delivery Rate

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

-- Open the fuel filler door.

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

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-- Disconnect the fuel line -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  .

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-- Attach the Pressure Tester Kit - Regulator Valve:VAS 6550/4  and hold the hose in a large, fuel-resistant measuring container.

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

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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:VAS 6550/4  as follows:

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

• The levers point in the flow direction.

-- Connect the Vehicle Diagnostic Tester.

-- Turn on the ignition and select the following menu items on the Vehicle Diagnostic Tester:

• OBD 
• Engine electronics 
• Basic setting 
• Empty fuel tank 

-- Push 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.

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• Specified value: 4.5 bar 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 700 cm³ /15 s.

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.
• Vehicle Diagnostic Tester is 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.

-- 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: 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.