Transfer Fuel Pump -G6- FUEL PRESSURE, CHECKING, ENGINE CODE CJAA

WARNING: This page is about a different car, the 2015 Volkswagen Beetle, 2014 Volkswagen Beetle, and 2013 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Diesel Pressure Tester KitVAS6551
Diesel Pressure Tester Kit - Adapter Set VAS6551/5
Trim Removal Wedge3409
Vehicle Diagnostic Tester

WARNING:

Remember, the fuel pump will turn on when a door is opened, if the battery is connected. Fuel may leak out when the system is open.

Test Conditions:

The battery voltage is minimum 12.5 V. Refer to BATTERY, CHECKING .
Voltage supply OK, refer to Fuel Pump -G6- VOLTAGE SUPPLY, CHECKING .
Fuel tank minimum ¹ /₂ full.
The ignition is off
All electrical consumers such as, for example, headlamps and rear window defogger, must be off.
Room temperature or fuel temperature: 20 ± 5 °C

NOTE:

The vehicle must be fueled with diesel fuel treated for the season. Under some conditions, summer diesel fuel can coagulate at low winter temperatures.

Diesel fuel bought in the summer can be filtered to 0 °C (32 °F).

Diesel fuel sold during the transition time can be filtered to -10 °C (14 °F).

Diesel fuel bought in the winter can be filtered to -20 °C (-4 °F).

If not sure, take a sample of the winter fuel and let it stand at low outside temperatures for approximately 1 hour. If the fuel coagulates at temperatures down to -20°C, then this diesel fuel is not suited for low temperatures. This coagulation can plug the screen in the fuel delivery unit as well as in the fuel filter.

Test Sequence

-- 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 .

-- Remove the engine cover. Refer to ENGINE COVER .

Vehicles with Engine Code CJAA

Fig 1: Identifying Fuel Supply Line -Arrow- To High Pressure Pump

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Open the clamp and remove the fuel supply line -arrow- from the high pressure pump.

-- Unlock and disconnect the connector from the Auxiliary Fuel Pump -V393- or from Fuel Pump 2 -V277- (inline electric fuel pump) inside the engine compartment.

Fig 2: Identifying Connector -A-

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Continuation for all Vehicles:

Fig 3: Identifying Diesel Pressure Tester Kit

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-- Insert the Diesel Pressure Tester Kit - Adapter Set - Adapter 1VAS6551/5-1 into the supply line and secure with a clamp.

-- Connect the Diesel Pressure Tester Kit - Hose 2VAS6551/2 between the Diesel Pressure Tester Kit - Adapter Set - Adapter 1VAS6551/5-1 and the connection >>A<< of the Diesel Pressure Tester KitVAS6551.

-- Connect the Diesel Pressure Tester Kit - Hose 1VAS6551/1 between the connection >>B<< of the Diesel Pressure Tester Kit - Adapter Set - Connection Hose 2VAS6551/5-2 and the high pressure pump.

-- Press the On/Off button to switch on the Diesel Pressure Tester KitVAS6551.

-- Open the shut-off valves -A- and -B- on the Diesel Pressure Tester KitVAS6551 in the direction of flow.

Fig 4: VAS 6551

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Close cut-off tap -C-.

-- Connect the Vehicle Diagnostic Tester and perform Guided Functions "check electric fuel pump(s)" .

NOTE:

The fuel pump now runs for 30 seconds.

Vehicles with engine code CJAA

-- Close the shut-off valve -B- for maximum 15 seconds.

The target value is minimum 0.5 bar:

Continuation for all vehicles

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 delivery quantity in front of the fuel filter as follows:

Check the fuel delivery quantity in front of the fuel filter:

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

Fig 5: Identifying Fuel Line Couplers

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

WARNING:

The fuel supply line is under pressure. 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. Remove the hose connection carefully to release the pressure.

-- Connect the Diesel Pressure Tester Kit - Hose 2VAS6551/2 between the supply line from the fuel tank and the connection -B- on the Diesel Pressure Tester KitVAS6551.

Fig 6: Identifying Diesel Pressure Tester Kit

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Connect the Diesel Pressure Tester Kit - Hose 1VAS6551/1 between the connection -A- on the Diesel Pressure Tester KitVAS6551 and the fuel line to the fuel filter.

-- Press the On/Off button to switch on the Diesel Pressure Tester KitVAS6551.

-- Open the shut-off valves -A- and -B- on the Diesel Pressure Tester KitVAS6551 in the direction of flow.

Fig 7: VAS 6551

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Close cut-off tap -C-.

-- Connect the Vehicle Diagnostic Tester and repeat Guided Function "check electric fuel pump(s)".

If the specification is now obtained:

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

If the specification is not obtained:

Proceed as follows to check the fuel delivery rate at the fuel delivery unit:

Check the fuel delivery quantity at the fuel delivery unit:

-- Remove the rear bench seat. Refer to REAR SEATS .

-- Unclip the locking flange cover -1- at the tabs -arrows- using the Trim Removal Wedge3409.

Fig 8: Identifying Right Cover

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

Fig 9: Fuel Lines At Flange

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

WARNING:

-- Connect the Diesel Pressure Tester KitVAS6551 between the fuel supply line and the fuel delivery unit using the Diesel Pressure Tester Kit - Hose 1VAS6551/1 and Pressure Tester Kit - Hose 2VAS6550/2.

Fig 10: Identifying Fuel Line And Fuel Delivery Unit

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Connect the Diesel Pressure Tester Kit - Hose 1VAS6551/1 -2- between the Diesel Pressure Tester KitVAS6551 -1- and the fuel delivery unit -5-.
Connect the Diesel Pressure Tester Kit - Hose 2VAS6551/2 -3- between the Diesel Pressure Tester KitVAS6551 -1- and the fuel delivery unit -4-.

-- Open the shut-off valve -A-.

Fig 11: VAS 6551

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Close the shut-off valves -B- and -C- on the Diesel Pressure Tester KitVAS6551.

-- Connect the Vehicle Diagnostic Tester and repeat Guided Function "check electric fuel pump(s)".

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.

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

Fig 12: Identifying Delivery Unit Fuel Hoses

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

If no fault was detected:

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