Test Sequence

WARNING: This page is about a different car, the 2015 Volkswagen Golf. However, it is still accessible from the selected car via links, so may be relevant.

-- Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

-- Follow the guidelines for clean working conditions. Refer to PARKING/AUXILIARY HEATER AND FUEL SYSTEM CLEAN WORKING CONDITIONS .

-- Turn off the ignition.

-- Remove the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

-- Open the clamp -arrow-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

WARNING:

Fuel Lines Are Under Pressure.

Danger of personal injury to eyes and skin.

Wear protective eyewear and protective clothing in order to avoid injury and contact with the skin. Wrap a cloth around the connection before loosening hose connections. Open the connection carefully and release the pressure.

-- Remove the fuel supply line -1- from the high pressure pump -2-.

-- Insert the :VAS6551/5-1 into the supply line -1- and secure with a clamp.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Connect the :VAS6551/2 between the :VAS6551/5-1 and the connection -A- of the :VAS6551 .

-- Connect the :VAS6551/5-2 between the connection -B- of the :VAS6551 and the high pressure pump -2-.

-- Secure the :VAS6551/5-2 on the high pressure pump -2- with a clamp.

-- Press the On/Off button to switch on the :VAS6551 .

-- Make sure that the drain valve -C- on the :VAS6551 -1- is closed.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- The shut-off valves -A- and -B- are opened on the :VAS6551 -1-.

-- Connect the Vehicle Diagnostic Tester.

-- Select Guided Function 01 Activate Fuel Pump .

-- Select Check Fuel Pump Delivery Pressure/Delivery .

-- Follow the instructions given by the Vehicle Diagnostic Tester.

NOTE:

The fuel pump is activated.

-- Read the fuel pressure in the :VAS6551 :

The target value is minimum 4.5 bar (65 psi):

If The Specification Is Not Obtained

-- Check the fuel lines inside the engine compartment for possible bends, blockages and damage.

-- Check the fuel lines inside the engine compartment for leaks.

If No Faults Are Detected:

Check the fuel pressure in front of the fuel filter as follows.

Check the Fuel Pressure in Front of the Fuel Filter

-- Disconnect the fuel supply line -1-. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, SEPARATING .

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

WARNING:

Fuel Lines Are Under Pressure.

Danger of personal injury to eyes and skin.

-- Connect the :VAS6551/2 between the fuel supply line from the fuel tank and the connection -B- on the :VAS6551 .

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Connect the :VAS6551/1 between the connection -A- on the :VAS6551 and the fuel line -1- to the fuel filter.

-- Press the On/Off button to switch on the :VAS6551 .

-- Make sure that the drain valve -C- on the :VAS6551 -1- is closed.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- The shut-off valves -A and B- are opened on the :VAS6551 -1-.

-- Repeat Check Fuel Pump Delivery Pressure/Delivery . Refer to FUEL PRESSURE, CHECKING .

If The Specification Is Now Obtained

Check and fuel filter and replace it, if necessary. Refer to FUEL FILTER .

If The Specification Is Not Obtained

Proceed as follows to check the fuel pressure at the fuel delivery unit.

Check the Fuel Pressure on the Fuel Delivery Unit

-- Remove the rear bench seat. Refer to BENCH SEAT/SINGLE SEAT, REMOVING AND INSTALLING .

-- Unclip the cover -1- at the tabs in direction of -arrows- using the :3409 .

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Unclip the grommet -1- downward out of the cover -2-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Guide the cover -2- on the wiring harness -3- downward.

-- If equipped unclip the connector -3- for the Metering Pump -V54- from the fuel delivery unit.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Lift the tab -2- in direction of -arrow A- making it possible to reach between the floor panel and the fuel tank.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- At the same time, pull the Fuel Pump Control Module -J538- -1- on the wiring harness -3- in direction of -arrow B- carefully out of the mount.

-- Remove the Fuel Pump Control Module -J538- toward the inside between the fuel tank and the floor panel.

-- Unlock and disconnect the fuel supply line -1- from the locking flange. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, SEPARATING .

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

WARNING:

Fuel Lines Are Under Pressure.

Danger of personal injury to eyes and skin.

-- Connect the :VAS6551/5-3 between the :VAS6551 and the fuel supply line to the fuel filter -2-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Connect the :VAS6551/5-4 between the :VAS6551 and the fuel delivery unit -1-.

-- Make sure that the drain valve -C- on the :VAS6551 -1- is closed.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- The shut-off valves -A and B- are opened on the :VAS6551 -1-.

-- Repeat Check Fuel Pump Delivery Pressure/Delivery . Refer to FUEL PRESSURE, CHECKING .

If Specified Value Is Achieved

-- Check the fuel lines to the engine compartment for possible bends, blockages and damage.

-- Check fuel lines for leaks.

If The Specification Is Not Obtained

-- Remove the fuel delivery unit. Refer to FUEL DELIVERY UNIT/FUEL LEVEL SENSOR, REMOVING AND INSTALLING .

-- Check the filter screen for dirt.

-- Check to make sure that all wires are connected properly.

-- Pull on the connections to make sure they are secure. Refer to FUEL DELIVERY UNIT/FUEL LEVEL SENSOR, REMOVING AND INSTALLING .

-- Make sure all the hoses are connected -arrows-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

If No Fault Was Detected

NOTE:

If the filter screen is not blocked or dirty, all lines are connected and the fuel pressure specified value is not reached, then the fuel delivery unit is faulty.

-- Replace the fuel delivery unit. Refer to FUEL DELIVERY UNIT/FUEL LEVEL SENSOR, REMOVING AND INSTALLING .