Engine Code BBW

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Fig 1: Identifying Special Tools - Fuel Pump, Checking (Engine Codes BBW)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools, testers and auxiliary items required

Union nut spanner 3217
Pressure gauge VAG 1318
Adapter VAG 1318/11
Hose adapter VAG 1318/16
Adapter VAG 1318/17
Adapter VAG 1318/23
Adapter VAG 1318/1

Fig 2: Identifying Special Tools - Fuel Pump, Checking (Engine Codes AEG, AVH, AZG, BEV, BBW)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools, testers and auxiliary items required

Torque wrench (40 to 200 Nm) VAG 1332
Remote control with adapter cable VAG 1348/3A VAG 1348/3-2
Test system VAG 1466 A
Diode test lamp VAG 1527 B
Adapter set VAG 1594 A
Multimeter VAG 1715 or Fluke 83 Multimeter
Measuring container
Wiring diagram

Requirements

Fig 3: Identifying Main Fuse Panel

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fuse No. 28 OK.
Battery voltage must be at least 11.5 V.
All electrical consumers, e.g. lights and rear window defroster, must be switched off.
If the vehicle is equipped with air conditioning, this must be switched off.

On models with an automatic transmission the selector lever must be in position "P" or "N".

NOTE:

Observe description of crash fuel shut-off function. Refer to Crash Fuel Shut-off under Crash fuel shut-off .

Checking Function and Voltage Supply

Remove cover from fuel delivery unit.
Briefly operate starter. Fuel pump must be heard to run
Switch off ignition.

If the fuel pump does not run:

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull fuse No. 28 out of fuse holder.
Connect remote control VAG 1348/3A with adapter cable VAG 1348/3-2 to contact 28a to fuel pump and battery positive (+).
Operate remote control.

Fuel pump runs:

Check activation of fuel pump relay referring to wiring diagram: Refer to Electrical Wiring Diagrams, Troubleshooting and Component Locations

Fuel pump does not run:

Fig 5: Installed Position Of Flange Of Fuel Delivery Unit

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Take 4-pin connector - 1 - off flange - 3 -.

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 diode test lamp VAG 1527 B with auxiliary cables from VAG 1594 A to outer contacts of connector.
Operate remote control. LED must light up

If LED does not light up:

Locate and eliminate open circuit using current wiring diagram: Refer to Electrical Wiring Diagrams, Troubleshooting and Component Locations

LED lights up (voltage supply OK.):

Fig 7: Fuel Delivery Connector & Seal

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove flange.
Check electrical wiring between flange and fuel pump for continuity.

If no open circuit can be found:

Fuel pump is faulty, replace fuel delivery unit. Refer to Fuel Delivery Unit, Removing and Installing under Fuel delivery unit, removing and installing .

Checking delivery rate

Requirements

Voltage supply OK.
Remote control VAG 1348/3A connected.

Work Sequence

Remove filler cap from fuel tank filler neck.

CAUTION:

The fuel system is under pressure! Before opening the system place a cloth around the connection. Then release the pressure by carefully loosening the connection.
Always wear eye protection and wear fuel-resistant gloves when disconnecting system connections.

Fig 8: Locating Supply Line, Union & Safety Ring

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull off supply line - 1 - and collect leaking fuel with a cloth.

NOTE:

To do this slide safety ring - 2 - into the union - 1 -.

Fig 9: Connecting VAG 1318 Components To Fuel Supply Line

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Connect pressure gauge VAG 1318 with adapter VAG 1318/23 and adapter VAG 1318/17 to fuel supply line.
Push hose adapter VAG 1318/16 onto adapter VAG 1318/11 on pressure gauge and hold hose in a measuring container.
Open shut-off tap on pressure gauge. Lever then points in direction of flow - A -.
Operate remote control VAG 1348/3A. Then close shut-off tap slowly until pressure gauge shows 3.5 bar pressure. From this point on do not alter setting of shut-off tap.

Empty measuring container.
Quantity of fuel delivered by fuel pump depends on battery voltage. Therefore connect multimeter to vehicle battery using adapter cables from VAG 1594 A.
Operate remote control for 30 seconds and measure battery voltage.

Fig 10: Fuel Delivery Chart (Engine Code BBW - 1 Of 2)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Compare quantity of fuel delivered with nominal value.

*) - Minimum delivery cm ³ /30 seconds

**) - Voltage at fuel pump with engine at rest and pump running (approx. 2 volts less than battery voltage).

Example:

During the test, a voltage of 12.0 volts is measured at the battery. As the voltage at the pump is approx. 2 volts less than the battery voltage, the result is a minimum delivery of approx. 500 cm ³ /30 seconds.

If the minimum delivery rate is not attained:

Check fuel pressure regulator.

Fuel pressure regulator is OK:

Check supply line to fuel tank for possible constrictions (kinks).

If supply line is OK:

Check fuel delivery rate before fuel filter.

Fig 11: Connecting Pressure Gauge VAG 1318 With Adapters

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull supply line - 1 - off fuel filter inlet. Refer to Fuel Delivery Unit, Removing and Installing under Fuel delivery unit, removing and installing .
Connect pressure gauge VAG 1318 with adapter VAG 1318/17 as shown.
Push adapter VAG 1318/1 onto adapter VAG 1318/11 on pressure gauge and hold hose in a measuring container.

The connector to the suction jet pump must be installed -.

Engage fuel delivery unit.
Connect fuel pump again to current supply.
Carefully pour in some fuel.
Cover flange opening (danger of spray).

Open shut-off tap on pressure gauge. Lever then points in direction of flow - A -.
Operate remote control VAG 1348/3A. Then close shut-off tap slowly until pressure gauge shows 3.5 bar pressure. From this point on do not alter setting of shut-off tap.
Empty measuring container.
Operate remote control again for 30 seconds.

Fig 12: Fuel Delivery Chart (Engine Code BBW - 2 Of 2)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Compare quantity of fuel delivered with nominal value.

*) - Minimum delivery cm ³ /30 seconds

**) - Voltage at fuel pump with engine at rest and pump running (approx. 2 volts less than battery voltage).

NOTE:

Due to the operating of the suction jet pump the minimum delivery rate before the fuel filter/pressure regulator is lower.

Example:

If minimum delivery rate is now attained:

Replace fuel filter.

If minimum delivery rate is again not attained:

Remove fuel delivery unit and check the strainer filter for soiling.

Only if you have not detected any faults up to now:

Replace fuel delivery unit.

If delivery rate has been attained but a fuel supply system fault is still suspected (e.g. intermittent failure of fuel supply system):

Check current draw of fuel pump as follows:
Install fuel delivery unit. Refer to Fuel Delivery Unit, Removing and Installing under Fuel delivery unit, removing and installing .

Fig 13: Checking Current Draw Of Fuel Pump Using Multimeter VAG 1715

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Connect multimeter VAG 1715 to wire - arrow - for contact 1 of 4-pin connector using current pick-up clamp.
Start engine and run at idling speed.
Check current draw of fuel pump. Specification: max. 9 amps

NOTE:

If the fuel system malfunction is intermittent, a check during a road test can be performed with the help of a 2nd person.

If current draw exceeds the specification:

Fuel pump is faulty, replace fuel delivery unit. Refer to Fuel Delivery Unit, Removing and Installing under Fuel delivery unit, removing and installing .

Checking Non-return Valve for Fuel Pump

Requirements

Remote control VAG 1348/3A connected.

Fig 14: Connecting Pressure Gauge VAG 1318 With Adapters

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Pull supply line - 1 - off fuel filter inlet. Refer to Fuel Delivery Unit, Removing and Installing under Fuel delivery unit, removing and installing .
Connect pressure gauge VAG 1318 with adapter VAG 1318/17 as shown.
Push adapter VAG 1318/1 onto adapter VAG 1318/11 on pressure gauge and hold hose in a measuring container.

The connector to the suction jet pump must be installed.

Engage fuel delivery unit.
Connect fuel pump again to current supply.
Carefully pour in some fuel.
Cover flange opening (danger of spray).

Close pressure gauge shut-off tap (lever diagonal to direction of flow (position - B - ).
Operate remote control at short intervals, until a pressure of approx. 4 bar has built up.

CAUTION: Danger of spray when opening the shut-off trap, hold container before connecting of pressure gauge.

If pressure builds up too high, lower excess pressure by carefully opening shut-off tap.
Observe pressure drop on gauge. Over a duration of 30 minutes pressure must not drop below 3.2 bar

If pressure drops further:

Check line connections for leaks.

If no wiring fault is detected:

Fuel pump is faulty, replace fuel delivery unit. Refer to Fuel Delivery Unit, Removing and Installing under Fuel delivery unit, removing and installing .