Checking the Fuel Delivery rate in the Engine Compartment:

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

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

-- Remove the Fuel Pump Control Module -J538- -2- from the cover -1-.

Fig 1: Identifying Cover With Fuel Pump Control Module J538

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

Fig 2: Identifying Right Cover

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-- Pull on the connector -arrow- without pressing the release to make sure the connection is secure.

Fig 3: Fuel Pump Control Module Connector

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If the connector was not connected correctly, it could cause a fault.

-- Release and disconnect the connector -arrow-.

-- Check the contacts on the connector and on the fuel delivery unit for damage.

-- Attach the : VAS5565 to the connector and to the fuel delivery unit.

Fig 4: Connecting Remote Control V.A.G 1348/3A To Test Instrument Adapter/DSO (5-Pin) VAS 5565 And To Battery Plus (+)

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-- Connect the : VAG1348/3A to the : VAS5565 and the battery positive terminal clamp in the engine compartment.

NOTE:

This step allows the fuel pump to run when the engine is not running.

-- The fuel pump delivery rate is dependent on the battery voltage. Also connect the Multimeter to the wires -1 and 5- in the : VAS5565 .

Fig 5: Connecting Multi-Meter To Wires -1 And 5- Of Adapter VAS 5565

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-- Remove the supply line -1-. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

Fig 6: Disconnecting Fuel Supply Line

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CAUTION:

The fuel system is under pressure.

Risk of injury from fuel spraying out.

Wear protective eyewear.
Wear safety gloves.
Reduce the pressure: place clean cloths around the connection point and carefully open the connection point.

-- Collect leaking fuel with a cleaning cloth.

-- Connect the : VAS6550/2 to the connection -A- on the : VAS6550 .

-- Connect the : VAS6550/4 to the : VAS6550 connection -B-.

Fig 7: Connect Fuel Line From Fuel Tank Using Pressure Tester Kit VAS 6550

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-- Connect the : VAS6550/2 to the fuel line from the fuel tank.

-- Hold the open end of the : VAS6550/4 hose in a measuring container.

-- Pull on the connector couplings to check them for secure fit.

-- Make sure that the drain valve -C- on the Pressure Tester -1- is closed.

Fig 8: Identifying Shut-Off Valves A And B On Pressure Tester Kit

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

-- Push the : VAG1348/3A .

NOTE:

The Transfer Fuel Pump -G6- is activated!

-- Adjust the pressure to 4.0 bar (58.01 psi) with the adjustment wheel on the Pressure Regulating Valve -arrow-.

Fig 9: Pressure Setting Knob

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-- From this point on do not move the adjustment wheel.

-- Empty the measuring container.

-- Press the remote control for 60 seconds while measuring the fuel pump voltage.

-- Compare the delivered quantity of fuel with the specified value in the table.

Fig 10: Identifying Graph Of Voltage Versus Delivery Rate

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Example:

During test, a voltage of 10.5 Volts is measured. This results in a minimum delivery quantity of approximately 1200 cm³ /60 s.

If Specified Value Is Not Reached:

Fig 11: Filler Cap

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-- Open the fuel filler door unit.

-- Clean the area around the fuel filler neck.

-- Remove the cap -arrow- for the fuel filler tube.

-- Check the fuel delivery rate again. Refer to Checking the Fuel Delivery rate in the Engine Compartment: .

If Specified Value Is Reached:

-- Check the fuel tank ventilation. Refer to FUEL TANK, CHECKING VENTILATION .

If Specified Value Is Not Reached:

-- Check the fuel lines for possible restrictions (kinks) or blockages.

-- Check the fuel lines for leaks and damage.

If No Error Can Be Found:

Proceed as follows to check the fuel delivery rate to the fuel filter.

Checking the Fuel Delivery Rate to the Fuel Filter:

Fig 12: Fuel Supply Line At Fuel Filter

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-- Disconnect the fuel supply line -arrow- from the fuel filter. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

CAUTION:

The fuel system is under pressure.

Risk of injury from fuel spraying out.

Wear protective eyewear.
Wear safety gloves.
Reduce the pressure: place clean cloths around the connection point and carefully open the connection point.

-- Connect the : VAS6550/1 to the connection -A- on the : VAS6550 .

-- Connect the : VAS6550/4 to the connection -B- on the : VAS6550 .

Fig 13: Connecting Pressure Tester Kit - Hose 1 VAS 6550/1

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Connect the Pressure Tester Kit to the fuel supply line -2- with the : VAS6550/1 .

-- Hold the open end of the : VAS6550/4 hose in a measuring container.

-- Make sure that the drain valve -C- on the Pressure Tester -1- is closed.

Fig 14: Identifying Shut-Off Valves A And B On Pressure Tester Kit

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Push the : VAG1348/3A .

NOTE:

The Transfer Fuel Pump -G6- is activated!

-- Adjust the pressure to 4.0 bar (58.01 psi) with the adjustment wheel on the Pressure Regulating Valve -arrow-.

Fig 15: Pressure Setting Knob

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- From this point on do not move the adjustment wheel.

-- Empty the measuring container.

-- Press the remote control for 60 seconds while measuring the fuel pump voltage.

If Specified Value Is Reached:

-- Check the fuel line to the engine for possible kinks or blockages.

-- Check the fuel line to the engine for leaks and damage.

If No Malfunction Was Detected:

-- Replace the fuel filter. Refer to FUEL FILTER, REMOVING AND INSTALLING .

If Specified Value Is Not Reached:

Check the fuel delivery rate on the fuel delivery unit as follows:

Fuel Delivery Rate, Checking on Fuel Delivery Unit:

Fig 16: Fuel Lines At Flange

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-- Pull the fuel line -1- off the flange. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

CAUTION:

The fuel system is under pressure.

Risk of injury from fuel spraying out.

Wear protective eyewear.
Wear safety gloves.
Reduce the pressure: place clean cloths around the connection point and carefully open the connection point.

-- Connect the : VAS6550/2 to the connection -A- on the : VAS6550 .

-- Connect the : VAS6550/4 to the connection -B- on the : VAS6550 .

Fig 17: Connect Pressure Tester Kit - Hose 1 VAS 6550/1

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Connect the : VAS6550 to the fuel delivery unit -1- with the : VAS6550/2 .

-- Hold the open end of the : VAS6550/4 hose in a measuring container.

-- Make sure that the drain valve -C- on the Pressure Tester -1- is closed.

Fig 18: Identifying Shut-Off Valves A And B On Pressure Tester Kit

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Push the : VAG1348/3A .

NOTE:

The Transfer Fuel Pump -G6- is activated!

-- Adjust the pressure to 4.0 bar (58.01 psi) with the adjustment wheel on the Pressure Regulating Valve -arrow-.

Fig 19: Pressure Setting Knob

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-- From this point on do not move the adjustment wheel.

-- Empty the measuring container.

-- Press the remote control for 60 seconds while measuring the fuel pump voltage.

If Specified Value Is Not Reached:

Fig 20: Identifying Delivery Unit Fuel Hoses

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

-- Check the fuel lines for possible restrictions (kinks) or blockages.

-- Remove the fuel delivery unit and check the filter screen for contamination.

-- Check the fuel lines for leaks and damage.

-- Check whether the hose connections -arrows- to the fuel delivery unit -1- are sealed.

If No Malfunction Was Detected:

-- Check the current draw of the fuel pump. Refer to CURRENT DRAW, CHECKING .

If No Error Was Detected during the Current Draw Test:

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

If the fuel delivery rate was reach, even though a fault in the fuel supply is still suspected (for example, intermittent loss of fuel supply):

-- Check the current draw of the fuel pump. Refer to CURRENT DRAW, CHECKING .

Tightening Specifications

Refer to OVERVIEW - FUEL DELIVERY UNIT/FUEL LEVEL SENSOR