Fuel Pump Check Valve, Checking

WARNING: This page is about a different car, the 2009 Volkswagen Rabbit, 2008 Volkswagen Rabbit, 2007 Volkswagen Rabbit, and 2006 Volkswagen Rabbit. However, it is still accessible from the selected car via links, so may be relevant.

-- Remove the rear seat bench. Refer to "Rear Seats" in Removal and Installation .

-- Remove the cover from the fuel delivery unit.

Fig 1: Identifying Cover From Fuel Delivery Unit

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 2: Identifying 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.

-- Connect 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 to battery positive (+).

WARNING:

The fuel supply line is under pressure. Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Wrap a cloth around the connection before disconnecting a fuel hose. Remove the hose connection carefully to release the pressure.

-- Disconnect the fuel supply line -arrow- from the fuel filter. Disconnecting the couplings, refer to COUPLING, DISCONNECTING .

Fig 4: Identifying Fuel Supply Line At Fuel Filter

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 5: Identifying Pressure Tester VAS 6550 Connected To Fuel Supply Line Using Hose VAS 6550/1

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Close the shut off lever -A- on the pressure tester VAS 6550 so the lever is perpendicular to the direction of flow.

-- Operate the remote control at short intervals, until a pressure of approximately 4 bar has built up.

WARNING:

Danger of spraying when opening the shut off lever; wear protective goggles and protective clothing to prevent injuries and contact with skin. Hold a container in front of the open connection of the pressure tester.

-- If pressure builds up too high, lower the excess pressure by carefully opening the shut off lever.

-- Watch the pressure decrease on the pressure tester. After 10 minutes the pressure must not drop below a 3 bar decrease.

If the pressure drops further:

-- Check the line connections for leaks.

If no fault is detected in the wiring:

-- Replace the fuel delivery unit, the fuel pump is faulty. Refer to FUEL DELIVERY UNIT/FUEL LEVEL SENSOR .