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Home >> Volkswagen >> 2018 >> Beetle S, 2D Hatchback >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 34 (Fuel Supply [CBTA, CBUA, CCTA, CBFA, CPLA, CPPA, CPRA, CPKA, DDSA] (Convertible)) >> 20 Fuel Supply >> Fuel Pump >> Transfer Fuel Pump -G6-, CHECKING >> Fuel Pressure, Checking

Fuel Pressure, Checking

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

Special tools and workshop equipment required 

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.
NOTE:

The connector couplings must >>audibly<< engage when locking.

Note the color coding when installing the connector coupling. Refer to Connector Coupling Allocation !

Pull on the connector coupling to check for secure fit.

Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS .

NOTE:

Pay attention to 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 .

-- Disconnect the supply line (metal coupling) -1- and wipe up any leaking fuel with a cloth. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS .

Fig 1: Disconnecting Fuel Supply Line
GWWN10-10528Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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

Fig 2: Identifying Pressure Tester Kit - Hose 1 VAS 6550/1
GWWN20-11024Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Connect the : VAS6550/1  to the fuel supply line -1- to the engine.

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

-- 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 3: Identifying Shut-Off Valves A And B On Pressure Tester Kit
GWWN20-11041Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Activate the fuel pump using the output diagnostic test mode to build the fuel pressure. 

-- Read the fuel pressure on the pressure gauge.

Specified Value:

If the fuel pressure is OK, check the residual pressure. Refer to RESIDUAL PRESSURE, CHECKING .

If the Specified Value is Exceeded:

-- Check the return line between the fuel filter and the fuel pump for kinks or blockages.

If No Faults Are Detected:

-- Pressure relief valve in fuel filter faulty, replace the fuel filter. Refer to FUEL FILTER, REMOVING AND INSTALLING .

If Specified Value Is Not Reached:

-- Check the fuel pressure in front of the fuel filter as follows:

Fuel Pressure, Checking before Fuel Filter:

Fig 4: Fuel Supply Line At Fuel Filter
GWWN20-10629Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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

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

Fig 5: Connecting Pressure Tester VAS 6550 Between Fuel Filter And Fuel Supply Line Using Hoses VAS 6550/1 And VAS 6550/2
GWWN20-10630Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Connect the : VAS6550  between the fuel filter and the fuel supply line using the : VAS6550/1  and the : VAS6550/2  .

-- 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 6: Identifying Shut-Off Valves A And B On Pressure Tester Kit
GWWN20-11041Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Activate the fuel pump using the output diagnostic test mode to build the fuel pressure.

-- Repeat the fuel pump output diagnostic test mode to build the fuel pressure. Refer to FUEL PRESSURE, CHECKING - Activate the fuel pump using the output diagnostic test mode to build the fuel pressure. .

If Specified Value Is Reached:

-- Check the fuel line between the fuel filter and the engine compartment for possible kinks or blockages.

-- Check the fuel line between the fuel filter and the engine compartment for leaks and damage.

If No Faults Can Be Found:

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

-- Pressure relief valve in fuel filter faulty, replace the fuel filter. Refer to FUEL FILTER, REMOVING AND INSTALLING .

If Specified Value Is Not Reached:

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

Checking the Fuel Pressure at the Fuel Delivery Unit:

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

-- If equipped, remove the Fuel Pump Control Module -J538- -2- from the cover -1-.

Fig 7: Identifying Cover With Fuel Pump Control Module J538
GWWN20-0603Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 8: Identifying Right Cover
GWWA20-10835Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the fuel lines -1- from the flange. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS .

Fig 9: Fuel Lines At Flange
GWWN20-10624Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
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- between the fuel line and the fuel delivery unit using the : VAS6550/1  and : VAS6550/2  .

Fig 10: Identifying Fuel Line And Fuel Delivery Unit
GWWM20-10042Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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 11: Identifying Shut-Off Valves A And B On Pressure Tester Kit
GWWN20-11041Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Activate the fuel pump with the output diagnostic test mode to build fuel pressure. Refer to FUEL PRESSURE, CHECKING - Activate the fuel pump using the output diagnostic test mode to build the fuel pressure. .

If Specified Value Is Reached:

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

-- Check the fuel line for leaks and damage.

If Specified Value Is Not Reached:

-- Remove the fuel delivery unit. Refer to FUEL DELIVERY UNIT/FUEL LEVEL SENSOR, REMOVING AND INSTALLING  and inspect it for debris.

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

Fig 12: Identifying Delivery Unit Fuel Hoses
GWWN20-10452Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Check the fuel lines for leaks and damage.

If No Error Can Be Found:

-- If the fuel pump is faulty, replace the fuel delivery unit. Refer to FUEL DELIVERY UNIT/FUEL LEVEL SENSOR, REMOVING AND INSTALLING .

Tightening Specifications 

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