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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 Repair Information.

-- Remove the floor sealing cover -1-.

Fig 1: Identifying 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: Connecting Jumper Cable From A Electrical Connector Test Lead Set Connected To Terminal Of 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. Then release the pressure by carefully loosening the connection.

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

Fig 4: Disconnecting Fuel Return Line By Pressing Release Buttons

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: Identifying Adapter V.A.G 1318/17-1 Connected To Disconnected Fuel Return Line And Placed 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 s).

Fig 6: Identifying 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 Repair Information.

If the fuel pump is faulty;

-- Replace the fuel pump. Refer to the Repair Information.

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

-- Install the rear seat bench. Refer to the Repair Information.