Delivery Quantity, Checking

WARNING: This page is about a different car, the 2010 Volkswagen Jetta, 2009 Volkswagen Jetta, 2009 Volkswagen GLI, 2008 Volkswagen Jetta, and 2008 Volkswagen GLI. However, it is still accessible from the selected car via links, so may be relevant.

Test Conditions:

Voltage supply is OK.
Fuel filter is OK.

-- Remove the bench seat. Refer to Removal and Installation .

-- Remove the cover -1- and the fuel pump control module -J538- -2- from the fuel delivery unit.

Fig 1: Identifying Cover With Fuel Pump Control Module J538

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- First, pull on the connector -arrow- without pressing the retainer to make sure it is connected securely. If the connector was not connected correctly, it could cause a fault.

Fig 2: Fuel Pump Control Module Connector

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the connector -arrow-.

-- Check the contacts on the connector and the fuel delivery unit for damage.

-- Install the test instrument adapter/DSO (5-pin) VAS 5565 between the connectors on the fuel delivery unit and cover.

Fig 3: Connecting Remote Control V.A.G 1348/3A To Test Instrument Adapter/DSO (5-Pin) VAS 5565 And To Battery Plus (+)

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Connect the remote control V.A.G 1348/3A to the test instrument adapter/DSO (5-pin) VAS 5565 and the battery positive terminal in the engine compartment.

NOTE:

This step allows the fuel pump to run when the engine is not running.

WARNING:

The fuel system is under pressure!

Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin.
Before loosening line connections, place a cloth around the connection point. Then release pressure by carefully pulling off the line.

-- Disconnect the fuel supply line -2-. Push the locking ring upward and into the housing.

Fig 4: Disconnecting Ventilation Line

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Connect the pressure tester VAS 6550 and the hose VAS 6550/2 to the fuel supply line. Hold the other end of the hose VAS 6550/1 in a measuring container.

Fig 5: Connecting Pressure Tester VAS 6550 To Fuel Supply Line Using Adapter VAS 6550/2 And Holding Adapter VAS 6550/1 In Measuring Container

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Make sure the drain is closed and the shut off levers are open.

WARNING:

Danger of spraying. Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Hold the container in front of the free connection of the pressure measuring device.

-- Operate the remote control V.A.G 1348/3A. Slowly close the shut off lever -arrow- until the pressure tester shows 4 bar. From this point on do not move the position of the shut off lever.

-- Empty the measuring container.

-- The fuel delivery rate of the fuel pump is dependent on battery voltage. So, connect the multi-meter V.A.G 1715 to connectors -1 and 5- of the test instrument adapter/DSO (5-pin) VAS 5565.

Fig 6: Connecting Multi-Meter V.A.G 1715 To Wires And Of Test Instrument Adapter/DSO (5-Pin) VAS 5565

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Operate the remote control for 60 seconds and simultaneously measure the voltage on the fuel pump.

-- Compare the quantity of fuel delivered with the specification.

Fig 7: Identifying Graph Of Voltage Versus Delivery Rate

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

*) Minimum delivery rate cm³ /60 s

**) Voltage on the fuel pump with engine running in idle and the pump is on.

Example:

During the test, a voltage of 10.5 volts is measured. This results in a minimum delivery quantity of approximately 1200 cm³ /60 s.

If the specification is not obtained:

-- Check the fuel lines for possible restrictions (kinks) or blockages.

If no malfunction can be found:

-- Remove the cap for the fuel filler neck and repeat the test. If the fuel delivery quantity is now reached, check the fuel tank ventilation.

If the specification is again not obtained:

-- Check the fuel filter as follows:

WARNING:

The fuel system is under pressure!

Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin.
Before loosening line connections, place a cloth around the connection point. Then release pressure by carefully pulling off the line.

-- Disconnect the fuel supply line -arrow- from the fuel filter.

Fig 8: Fuel Supply Line At Fuel Filter

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Connect the pressure tester VAS 6550 and the hose VAS 6550/1 to the fuel supply line. Hold the other end of the hose VAS 6550/2 in a measuring container.

Fig 9: Connecting Pressure Tester VAS 6550 To Fuel Supply Line Using Hose VAS 6550/1

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Make sure the drain is closed and the shut off levers are open.

-- Operate the remote control V.A.G 1348/3A. Slowly close the shut off lever -arrow- until the pressure tester shows 4 bar. From this point on do not move the position of the shut off lever.

-- Empty the measuring container.

-- Repeat the fuel delivery test.

If the minimum delivery rate is now obtained:

-- Replace the fuel filter.

If minimum delivery rate is again not obtained:

-- Remove the fuel delivery unit and check the fuel strainer for contamination.

Only when up to now no malfunction has been detected:

-- Replace the fuel delivery unit.

If the delivery rate has been obtained, but malfunctions are still suspected in the fuel supply (for example, intermittent loss of fuel supply):

-- Check the fuel pump current draw. Refer to CURRENT DRAW, CHECKING .