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Fuel Pump Delivery Quantity, Checking

Special Tools And Workshop Equipment Required

Switched remote control (jumper).
Multimeter.
Electrical connector test lead set.
Fuel pressure test set.
Measuring container, fuel-resistant.

Test Conditions

Battery voltage 12.5 V
Fuel filter OK
Fuel tank at least ¹ /₄ filled.
Fuel pressure regulator OK.
Ignition switched off.

Test Procedure

-- Perform a preliminary check to verify the customers complaint. Refer to PRELIMINARY CHECK

Start Diagnosis

-- Remove the fuel filler cap from fuel filler tube.

-- Remove rear seat bench. Refer to the appropriate Service Information.

-- Remove the floor sealing cover -1-.

Fig 1: Fuel Pump Control Module, Retaining Clips & Floor Sealing Cover

GWWM20-0321

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the electrical harness connector -arrow- from the fuel delivery unit.

Fig 2: Identifying Fuel Delivery Unit Connector

GWWA20-1067

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Connect a switched remote control (jumper) to terminal -1- of the fuel delivery unit and to vehicle Battery (+).

-- Connect a jumper wire from terminal -5- of the fuel delivery unit to vehicle Ground.

Fig 3: A Jumper Cable From A Electrical Connector Test Lead Set Connected To Terminal Of The Fuel Delivery Unit And To Vehicle Ground

GWWA20-1120

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

WARNING:

Fuel system is under pressure! Before opening the system, place rags around the connection area. Always wear safety goggles. Then release the pressure by carefully loosening the connection. Refer to the appropriate Service Information.

-- Disconnect the fuel return line -arrow- by pressing release buttons.

Fig 4: Fuel Return Line

GWWA20-1212

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Connect a fuel line from the fuel pressure test set to the disconnected fuel return line and hold it in the measuring container.

Fig 5: Connecting Fuel Line From High Pressure Fuel Gauge To Disconnected Fuel Return Line And Hold It In Measuring Container

GWWA20-1096

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Press the switch on the remote control (jumper) and operate the fuel pump for 15 seconds.

-- Compare quantity of fuel delivered with minimum delivery rate in the diagram (cm³ /30 sec.).

Fig 6: Fuel Quantity Graph

GWWN20-10138

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

Voltage at the fuel pump with engine stopped and fuel pump running is approx. 2 volts less than Battery voltage.

If minimum delivery quantity is not obtained, the following malfunctions may be present:

Fuel lines pinched.
Fuel filter plugged.
Fuel pump faulty.

-- If necessary, repair any pinched or plugged lines.

If the filter is restricted;

-- Replace the fuel filter. Refer to the appropriate Service Information.

If the fuel pump is faulty;

-- Replace the fuel pump. Refer to the appropriate Service Information.

Assembly is performed in reverse order of removal. Note the following:

-- Install the rear seat bench. Refer to the appropriate Service Information.

Final Procedures

After the repair work, the following work steps must be performed in the following sequence:

Check the DTC memory. Refer to DIAGNOSTIC MODE 03 - READ DTC MEMORY .
If necessary, erase the DTC memory. Refer to DIAGNOSTIC MODE 04 - ERASE DTC MEMORY .
If the DTC memory was erased, generate readiness code. Refer to READINESS CODE .