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Home >> Volkswagen >> 2006 >> GTI 1.8 E, Automatic >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 23 (2.0L - Fuel Supply - Engine Code(S): BPY (As Of 12.2010)) >> 20 Fuel Supply >> Diagnosis And Testing >> Fuel Pump, Checking >> Fuel Delivery, Checking

Fuel Delivery, Checking

WARNING: This page is about a different variant/trim than selected.

-- Remove the rear 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
GWWN20-0603Courtesy of VOLKSWAGEN UNITED STATES, 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
GWWN20-10623Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Disconnect the connector.

-- 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 cover and the fuel delivery unit.

Fig 3: Connecting Remote Control V.A.G 1348/3A To Test Instrument Adapter/DSO (5-Pin) VAS 5565 And To Battery Plus (+)
GWWN20-10422Courtesy of VOLKSWAGEN UNITED STATES, 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:

Fuel system is under pressure!

  • Always wear protective eye-wear 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 supply line (metal coupling) -arrow- and wipe up any leaking fuel with a cloth.

Fig 4: Disconnecting Supply Line And Catch Escaping Fuel Using Rag
GWWA20-10135Courtesy of VOLKSWAGEN UNITED STATES, INC.
NOTE:

Press the locking ring to release the fuel line.

-- Connect the pressure tester VAS 6550 to the fuel supply line using the hose VAS 6550/2. 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 Hose VAS 6550/2
GWWN20-10631Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

WARNING:

Danger of spraying. Always wear protective eye-wear 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 shutoff lever -arrow- until the pressure tester shows 4 bar. From this point on do not move the position of the shutoff 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 wires -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
GWWN20-10423Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Operate the remote control for 30 seconds and simultaneously measure voltage on the fuel pump.

-- Compare the quantity of fuel delivered with specification.

Fig 7: Fuel Quantity Graph
GWWN20-10138Courtesy of VOLKSWAGEN UNITED STATES, INC.

*) Minimum delivery rate cm3 /30 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 580cm3 /30 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 from 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:

Fuel system is under pressure!

  • Always wear protective eye-wear 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
GWWN20-10629Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Connect the pressure tester VAS 6550 to the fuel supply line using the hose VAS 6550/1. 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
GWWN20-10632Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

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

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