Fuel Pump (FP), checking: Notes

WARNING: This page does not describe the selected car, but rather 14 other vehicles, including the 2005 Volkswagen GTI, 2004 Volkswagen R32, 2004 Volkswagen Jetta, 2004 Volkswagen GTI, and 2003 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Special Tools -- Fuel Pump, Checking (1 Of 2)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Recommended special tools and equipment

3217 ring nut wrench
V.A.G 1318 pressure gauge
V.A.G 1318/11 adapter
V.A.G 1318/16 hose adapter
V.A.G 1318/17 adapter
V.A.G 1318/23 adapter

Fig 2: Identifying Special Tools -- Fuel Pump, Checking (2 Of 2)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

V.A.G 1332 torque wrench (40 to 200 Nm)
V.A.G 1348/3A remote control with V.A.G 1348/3-2 adapter cable
V.A.G 1466 electrical circuit tester
V.A.G 1527B voltage tester

V.A.G 1594A connector test kit
V.A.G 1715 multimeter
Measuring container
Wiring diagram

Test requirements

Fig 3: Identifying Main Fuse Panel

Courtesy of VOLKSWAGEN UNITED STATES, INC.

The respective fuse no. 28 of Fuel Pump (FP) -G6- must be OK:

Refer to Electrical Wiring Diagrams, Troubleshooting & Component Locations

Battery voltage must be at least 11.5 volts.
All electrical consumers such as, for example, lights and rear window defroster must be switched off.
Parking brake must be engaged or else daylight driving lights will be switched on.
For vehicles with automatic transmission, selector lever must be in -P-.

Ground (GND) connections between engine and chassis must be OK.

NOTE: Note function description of crash fuel shut-off. Refer to Crash fuel shut-off .

Checking function and voltage supply

Fold rear seatback forward.
Remove cover from Fuel Pump (FP) unit
Operate starter briefly. Fuel pump must

audibly

Switch ignition off.

If Fuel Pump (FP) does not start up:

Remove cover in front of fuse holder.

Fig 4: Connecting VAG 1348/3A With Adapter Cable VAG 1348/3-2 To Contact And Battery Positive

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Remove fuse no. 28 from fuse holder.
Connect V.A.G 1348/3A remote control to Fuel Pump (FP) and B+ at terminal 28a using V.A.G 1348/3-2 remote control connection.
Operate remote control.

If Fuel Pump (FP) runs:

Check activation of Fuel Pump (FP) Relay -J17- according to wiring diagram:

Refer to Electrical Wiring Diagrams, Troubleshooting & Component Locations

If Fuel Pump (FP) does not run:

Fig 5: Fuel Delivery Connector

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect 4-pin harness connector from flange at Fuel Pump (FP) unit -arrow-.

Fig 6: Connecting Diode Test Lamp VAG 1527 B With Auxiliary Cables From VAG 1594 A To Outer Contacts Of Connector

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Connect V.A.G 1527 diode test lamp to the outer terminals of the connector.
Operate remote control.

LED must light up.

LED does not light up:

Locate and repair open circuit using wiring diagram:

Refer to Electrical Wiring Diagrams, Troubleshooting & Component Locations

LED lights up (voltage supply OK):

Fig 7: Removing/Installing Union Nut With Wrench 3217

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Use 3217 ring nut wrench to remove union nut.
Check whether electrical wires between flange and Fuel Pump (FP) are connected.

If there are no open circuits:

Fuel Pump (FP) malfunctioning, replace Fuel Pump (FP) unit. Refer to Fuel Pump (FP) unit, removing and installing , Fuel Pump (FP) unit, removing and installing.
Erase DTC memory of Engine Control Module (ECM). Refer to Diagnostic mode 4: Reset/erase diagnostic data
Generate readiness code. Refer to Readiness code, generating