Transfer Fuel Pump -G6- Fuel Delivery Rate, 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 Kit VAS 6551
Diesel Pressure Tester Kit - Adapter Set VAS 6551/5
Trim Removal Wedge 3409
Hose Clip Pliers VAG 1921
Pressure Regulator Valve VAS 6551/6
Vehicle Diagnostic Tester - Test Adapter - 5 Pin VAS 5565
Analog/Digital Multimeter FLU 83III
Vehicle Diagnostic Tester
Measuring Container, Minimum Capacity: 3 liters

Test Conditions:

The battery voltage is minimum 12.5 V. Refer to REMOVAL AND INSTALLATION .
Voltage supply OK, refer to FUEL PUMP -G6- VOLTAGE SUPPLY, CHECKING .
The fuel filter is OK.
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.

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 (-4°F), 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.

WARNING: The fuel supply line remains 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.

-- Remove the engine cover. Refer to REMOVAL AND INSTALLATION .

-- Move the right front seat all the way forward.

-- Remove the rear bench seat. Refer to REMOVAL AND INSTALLATION .

-- Unclip the locking flange cover -1- at the tabs -arrows- using the Trim Removal Wedge 3409.

Fig 1: Identifying Right Cover

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-- Pull on the connector -arrow- without pressing the release to make sure the connection is secure. If the connector was not connected correctly, it could cause a fault.

Fig 2: Fuel Pump Control Module Connector

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-- Fuel delivery rate of the fuel pump is dependent on battery voltage. Connect the Analog/Digital Multimeter FLU 83III to connectors -1- and -5- on the Vehicle Diagnostic Tester - Test Adapter - 5 Pin VAS 5565.

Fig 3: Connecting Multi-Meter To Terminals 1 And 5 Of Test Instrument Adapter/DSO (5-Pin) VAS 5565

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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.

Vehicles with engine code CJAA:

Fig 4: Identifying Fuel Supply Line To High Pressure Pump

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

Continuation for all vehicles

Fig 5: Identifying Diesel Pressure Tester Kit - Adapter Set - Adapter 1

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-- Insert the Diesel Pressure Tester Kit - Adapter Set - Adapter 1 VAS 6551/5-1 into the fuel supply line and secure with a clamp.

-- Connect the Diesel Pressure Tester Kit - Hose 2 VAS 6551/2 between the Diesel Pressure Tester Kit - Adapter Set - Adapter 1 VAS 6551/5-1 and the connection -A- on the Diesel Pressure Tester Kit VAS 6551.

-- Connect the Pressure Regulator Valve VAS 6551/6 to the connection -B- on the Diesel Pressure Tester Kit VAS 6551.

-- Hold the open end of the Pressure Regulator Valve VAS 6551/6 hose in a measuring container.

-- Press the On/Off button to switch on the Diesel Pressure Tester Kit VAS 6551.

-- Open the shut-off valves -A- and -B- on the Diesel Pressure Tester Kit VAS 6551 in the direction of flow.

Fig 6: VAS 6551

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-- 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.

-- Set the pressure to 0.5 bar using the Pressure Regulator Valve VAS 6551/6.

Fig 7: Identifying Pressure Regulator Valve

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-- The initial pressure is set by turning the adjusting wheel -arrow- on the Pressure Regulator Valve VAS 6551/6.

Engine code CJAA 0.5 bar

-- Empty the measuring container.

-- Perform Guided Function "activate fuel pump (check fuel)" on the vehicle diagnostic tester.

-- Read the specified fuel quantity in the Diesel Pressure Tester Kit VAS 6551.

Engine code CJAA

Fig 8: Identifying Fuel Quantity Graph

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-- Compare the supplied fuel quantity with the value in the table.

*) supplied fuel quantity in ml/30 s

**) Voltage on the fuel delivery unit (V) with engine running in idle and the pump is on.

Specified value: minimum 1000 ml/30 seconds.

Example:

12.0 V is measured on the fuel delivery unit during the test.

A supplied fuel quantity of 1100 ml/30 s results.

If the minimum delivery rate is not attained:

-- 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 malfunction can be found:

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 9: Identifying Fuel Line Couplers

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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.

-- Connect the Diesel Pressure Tester Kit - Hose 2 VAS 6551/2 to the fuel supply line coming from the fuel tank.

Fig 10: Identifying Diesel Pressure Tester Kit - Hose 2

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-- Connect the Diesel Pressure Tester Kit - Hose 2 VAS 6551/2 to the connection -A- on the Diesel Pressure Tester Kit VAS 6551.

-- Connect the Pressure Regulator Valve VAS 6551/6 to the connection -B- on the Diesel Pressure Tester Kit VAS 6551.

-- Hold the open end of the Pressure Regulator Valve VAS 6551/6 hose in a measuring container.

-- Press the On/Off button to switch on the Diesel Pressure Tester Kit VAS 6551.

-- Make sure that the drain valve -C- on the Diesel Pressure Tester Kit VAS 6551 -1- is closed.

Fig 11: Identifying Shut-Off Valves A And B On Pressure Tester Kit

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-- The shut-off valves -A- and -B- are opened on the Diesel Pressure Tester Kit VAS 6551 -1-.

-- Close cut-off tap -C-.

-- Connect the vehicle diagnostic tester and repeat Guided Function "check electric fuel pump(s)".

If the minimum delivery rate is now obtained:

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

If specified value is again 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 REMOVAL AND INSTALLATION .

-- Unclip the cover -1- at the tabs -arrows- using the Trim Removal Wedge 3409.

Fig 12: Identifying Right Cover

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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.

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

Fig 13: Fuel Lines At Flange

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WARNING:

Fuel lines are under pressure.

Danger of personal injury to eyes and skin.

-- Connect the Diesel Pressure Tester Kit - Hose 2 VAS 6551/2 to the connection for the fuel supply line on the fuel delivery unit.

Fig 14: Identifying Diesel Pressure Tester Kit - Hose 2

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-- Connect the Diesel Pressure Tester Kit - Hose 2 VAS 6551/2 to the connection -A- on the Diesel Pressure Tester Kit VAS 6551.

-- Connect the Pressure Regulator Valve VAS 6551/6 to the connection -B- on the Diesel Pressure Tester Kit VAS 6551.

-- Hold the open end of the Pressure Regulator Valve VAS 6551/6 hose in a measuring container.

-- Press the On/Off button to switch on the Diesel Pressure Tester Kit VAS 6551.

-- Make sure that the drain valve -C- on the Diesel Pressure Tester Kit VAS 6551 -1- is closed.

Fig 15: Identifying Shut-Off Valves A And B On Pressure Tester Kit

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-- The shut-off valves -A- and -B- are opened on the Diesel Pressure Tester Kit VAS 6551 -1-.

-- Close cut-off tap -C-.

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

If the minimum delivery rate is now obtained:

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

-- Check fuel lines for leaks.

If specified value is again 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 16: Identifying Delivery Unit Fuel Hoses

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Only when up to now no malfunction has been detected:

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