Fuel Delivery Rate, Checking

Special tools and workshop equipment required

Trim Removal Wedge 3409
Remote Control VAG 1348/3A
Analog/Digital Multimeter FLU83III
Vehicle Diagnostic Tester - Test Adapter - 5 PinVAS5565
Pressure Tester Kit VAS6550
Pressure Tester Kit - Pressure Regulator Valve VAS6550/4
Measuring Container, 3 Liter

NOTE:

The coupling must audibly engage when locking.

Note the color coding when installing the coupling, refer to Coupling Allocation !

Pull on the coupling to make sure it is secure.

Disconnecting the coupling, refer to COUPLING, DISCONNECTING .

If driving is still impaired with the fuel tank 1/4 full, then perform a fuel delivery test with the fuel tank only 1/4 full or with very little fuel in the fuel tank.

Test Conditions:

Voltage supply OK, refer to FUNCTION AND VOLTAGE SUPPLY, CHECKING .
Fuel pressure OK, refer to FUEL PRESSURE, CHECKING .
The battery voltage must be at least 11.5 V. Charge if necessary, refer to BATTERY, CHARGING .
Fuel Pump Control Module -J538- fuse OK, refer to appropriate System Wiring Diagram Information.
Fuel Pump Control Module -J538- is OK, using the Vehicle Diagnostic Tester.
Fuel Pump Relay -J17- OK, using the Vehicle Diagnostic Tester
Fuel pump fuse OK, refer to appropriate System Wiring Diagram Information
Pull on the connector without pressing the release to make sure the connection is secure. Repeat the fuel pump functionality test if the connector was not connected correctly.
Fuel level inside the fuel tank is above reserve

Test Sequence:

-- Follow all safety precautions, refer to SAFETY PRECAUTIONS .

-- Follow the guidelines for clean working conditions, refer to FUEL SYSTEM CLEAN WORKING CONDITIONS .

-- Remove the rear seat bench, refer to "Rear Seats" in Removal and Installation .

-- Remove the carpet and fold it upward.

-- Remove the right cover and the fuel pump control module -2- from the opening above the fuel delivery unit.

Fig 1: Identifying Cover With Fuel Pump Control Module J538

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 2: Identifying Right Cover

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-- Disconnect the connector -1- from the flange -3-.

Fig 3: Identifying Connector -1-, Fuel Line -2- And Fuel Delivery Unit -3-

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

-- Install the Vehicle Diagnostic Tester - Test Adapter - 5 Pin VAS5565 between the connectors on the fuel delivery unit and cover.

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Connect the Injection Rate Comparison Meter Kit - Remote Cable VAG1348/3A to the Vehicle Diagnostic Tester - Test Adapter - 5 Pin VAS5565 and to the battery positive (+) terminal inside the engine compartment.

NOTE:

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

-- Fuel delivery rate of the fuel pump is dependent on battery voltage. Also connect the Analog/Digital Multimeter FLU83III to the wires -1- and -5- in the Vehicle Diagnostic Tester - Test Adapter - 5 Pin VAS5565.

Fig 5: Connecting Multi-Meter V.A.G 1715 To Wires And Of Test Instrument Adapter/DSO (5-Pin) VAS 5565

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

WARNING:

The 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 removing a fuel hose. Open the connection carefully and release the pressure.

-- Remove the supply line (metal coupling) -1-. Disconnect the connector couplings, refer to COUPLING, DISCONNECTING .

Fig 6: Identifying Supply Line (Metal Coupling)

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-- Wipe up any leaking fuel with a cloth.

-- Connect the Pressure Tester Kit - Hose 1VAS6550/1 to the connection -A- on the Pressure Tester Kit VAS6550.

Fig 7: Connect Fuel Line From Fuel Tank Using Pressure Tester Kit VAS6550

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Connect the fuel line from the fuel tank using the Pressure Tester KitVAS6550 via the Pressure Tester Kit - Hose 2VAS6550/2.

-- Connect the Pressure Regulator Valve VAS6550/4 to the connection -B- on the Pressure Tester Kit VAS6550.

-- Hold the open end of the Pressure Tester Kit - Pressure Regulator Valve VAS6550/4 hose in a measuring container.

-- Pull on the connector couplings to make sure they are secure.

-- Make sure that the drain valve -C- on the pressure tester (Diesel) -1- is shut.

Fig 8: 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 VAS6550 -1- are opened.

-- Push the Injection Rate Comparison Meter Kit - Remote Cable VAG1348/3A.

NOTE:

The Transfer Fuel Pump -G6- is activated!

-- Adjust the pressure to 4.0 bar with the adjustment wheel on the Pressure Regulator Valve VAS6550/4 -arrow-.

Fig 9: Pressure Setting Knob

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- From this point on do not move the pressure setting knob.

-- Empty measuring container.

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

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

Fig 10: Identifying Graph Of Voltage Versus Delivery Rate

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Axis designation	Unit
Minimum delivery rate	cm³
Fuel pump voltage when the engine is idling and the pump is running	Volt

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 the specification is not obtained:

Fig 11: Filler Cap

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Open the fuel filler door unit.

-- Clean the area around the fuel filler tube.

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

-- Check the fuel delivery rate again.

If specified value is achieved:

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

If the specification is not obtained:

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

-- Check the fuel lines for leaks and damage.

If no malfunction can be found:

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

-- Remove the fuel line -arrow- and wipe up the draining fuel with a clean cloth. Disconnect the connector couplings, refer to COUPLING, DISCONNECTING .

Fig 12: Identifying Fuel Line

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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 Pressure Tester KitVAS6550 with the Pressure Tester Kit - Hose 2VAS6550/2 to the flange.

Fig 13: Identifying Pressure Tester Kit VAS6550 With Pressure Tester Kit

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Connect the Pressure Tester Kit - Hose 2VAS6550/2 to the connection -A- on the Pressure Tester Kit VAS6550.

-- Connect the Pressure Regulator Valve VAS6550/4 to the connection -B- on the Pressure Tester Kit VAS6550.

-- Hold the open end of the Pressure Tester Kit - Pressure Regulator Valve VAS6550/4 hose in a measuring container.

-- Make sure that the drain valve -C- on the pressure tester (Diesel) -1- is shut.

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 VAS6550 -1- are opened.

-- Push the Injection Rate Comparison Meter Kit - Remote Cable VAG1348/3A.

NOTE:

The Transfer Fuel Pump -G6- is activated!

-- Adjust the pressure to 4.0 bar with the adjustment wheel on the Pressure Tester Kit - Pressure Regulator Valve VAS6550/4 -arrow-.

Fig 15: Pressure Setting Knob

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- From this point on do not move the pressure setting knob.

-- Empty measuring container.

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

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

Fig 16: Identifying Graph Of Voltage Versus Delivery Rate

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Axis designation	Unit
Minimum delivery rate	cm³
Fuel pump voltage when the engine is idling and the pump is running	Volt

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 the specification is not obtained:

-- Remove the fuel delivery unit and check the filter screen for dirt, refer to FUEL DELIVERY UNIT/FUEL LEVEL SENSOR .

-- Check the fuel lines for leaks and damage.

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

If no fault was detected:

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

If no faults were found while checking the current draw:

-- Replace the fuel delivery unit flange, refer to FUEL DELIVERY UNIT/FUEL LEVEL SENSOR .

NOTE:

The pressure relief valve and the fuel filter are integrated in the fuel delivery unit flange and cannot be replaced separately.

-- Repeat the fuel delivery rate test at the fuel delivery unit, refer to FUEL DELIVERY RATE, CHECKING .

If the specification is not obtained:

-- Replace the fuel delivery unit, refer to FUEL DELIVERY UNIT/FUEL LEVEL SENSOR .

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 fuel pump current draw, refer to CURRENT DRAW, CHECKING .

Special tools and workshop equipment required

Trim Removal Wedge 3409
Remote Control VAG1348/3A
Analog/Digital Multimeter FLU83III
Vehicle Diagnostic Tester - Test Adapter - 5 Pin VAS5565
Pressure Tester Kit VAS6550
Pressure Tester Kit - Pressure Regulator Valve VAS6550/4
Measuring Container, 3 Liter

NOTE:

The fuel delivery rate is first checked inside the engine compartment using Guided Functions "check fuel delivery rate, quick test". Perform a second measurement on the fuel delivery unit flange if the minimum delivery rate is not attained.

If driving is still impaired with the fuel tank ¹ /₄ full, then perform a fuel delivery test with the fuel tank only ¹ /₄ full or with very little fuel in the fuel tank.

The coupling must audibly engage when locking.

Note the color coding when installing the coupling, refer to Coupling Allocation !

Pull on the coupling to make sure it is secure.

Disconnecting the coupling, refer to COUPLING, DISCONNECTING .

Checking the amount of fuel in the measuring container:

-- Connect the Vehicle Diagnostic Tester to the vehicle.

-- Select the Guided Functions in the Vehicle Diagnostic Tester.

-- Perform vehicle identification.

-- Select engine .

-- Select check fuel delivery rate, quick test .

-- Follow the instructions for the Vehicle Diagnostic Tester.

If the specification is not obtained:

Fig 1: Filler Cap

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Open the fuel filler door unit.

-- Clean the area around the fuel filler tube.

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

-- Check the fuel delivery rate again.

If specified value is achieved:

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

If the specification is not obtained:

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

-- Check the fuel lines for leaks and damage.

If no malfunction can be found:

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

Check the fuel delivery quantity at the fuel delivery unit:

Test Conditions:

Voltage supply OK, refer to FUNCTION AND VOLTAGE SUPPLY, CHECKING .
Fuel pressure OK, refer to FUEL PRESSURE, CHECKING .
The battery voltage must be at least 11.5 V. Charge if necessary, refer to BATTERY, CHARGING .
Fuel Pump Control Module -J538- fuse OK, refer to appropriate System Wiring Diagram Information.
Fuel Pump Control Module -J538- is OK. Use the Vehicle Diagnostic Tester.
Fuel Pump Relay -J17- OK. Use the Vehicle Diagnostic Tester
Fuel pump fuse OK, refer to appropriate System Wiring Diagram Information
Pull on the connector without pressing the release to make sure the connection is secure. Repeat the fuel pump functionality test if the connector was not connected correctly.
Fuel level inside the fuel tank is above reserve

Test Sequence:

-- Follow all safety precautions, refer to SAFETY PRECAUTIONS .

-- Follow the guidelines for clean working conditions, refer to FUEL SYSTEM CLEAN WORKING CONDITIONS .

-- Remove the bench seat, refer to Rear Seats .

-- Remove the carpet and fold it upward.

-- Remove the right cover and the Fuel Pump Control Module -J538- -2- from the assembly opening above the fuel delivery unit.

Fig 2: Identifying Cover With Fuel Pump Control Module J538

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- To do this, unclip the right cover -1- at the tabs -arrows- using the Trim Removal Wedge 3409.

Fig 3: Identifying Right Cover

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Vehicles with Parking Heater

Fig 4: Identifying Parking Heater

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-- Disconnect the connector -1- from the cover -3-.

-- Release and disconnect the connector -1-.

-- Unclip the grommet -2- downward out of the cover -3-.

-- Remove the wiring harness downward.

-- Release and remove the fuel extraction line -2- from the flange -1-. Disconnect the connector couplings, refer to COUPLING, DISCONNECTING .

Fig 5: Identifying Fuel Extraction Line

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Continuation for All Vehicles

Fig 6: Identifying Connector -1-, Fuel Line -2- And Fuel Delivery Unit -3-

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-- Disconnect the connector -1- from the flange -3-.

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

-- Attach the Vehicle Diagnostic Tester - Test Adapter - 5 Pin VAS5565 to the connector and to the fuel delivery unit.

Fig 7: Connecting Remote Control V.A.G 1348/3A To Test Instrument Adapter/DSO (5-Pin) VAS 5565 And To Battery Plus (+)

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Connect the Injection Rate Comparison Meter Kit - Remote Cable VAG1348/3A to the Vehicle Diagnostic Tester - Test Adapter - 5 Pin VAS5565 and the battery positive terminal clamp in the engine compartment.

NOTE:

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

Fig 8: Connecting Multi-Meter V.A.G 1715 To Wires And Of Test Instrument Adapter/DSO (5-Pin) VAS 5565

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

WARNING:

Fuel lines are under pressure.

Danger of personal injury to eyes and skin.

-- Remove the fuel line -arrow- and wipe up the draining fuel with a clean cloth. Disconnect the connector couplings, refer to COUPLING, DISCONNECTING .

Fig 9: Identifying Fuel Line

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Connect the Pressure Tester Kit VAS6550 with the Pressure Tester Kit - Hose 2VAS6550/2 to the flange.

Fig 10: Identifying Pressure Tester Kit VAS6550 With Pressure Tester Kit

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Connect the Pressure Tester Kit - Hose 2VAS6550/2 to the connection -A- on the Pressure Tester Kit VAS6550.

-- Connect the Pressure Tester Kit - Pressure Regulator Valve VAS6550/4 to the connection -B- on the Pressure Tester Kit VAS6550.

-- Hold the open end of the Pressure Tester Kit - Pressure Regulator Valve VAS6550/4 hose in a measuring container.

-- Make sure that the drain valve -C- on the pressure tester (Diesel) -1- is shut.

Fig 11: 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 VAS6550 -1- are opened.

-- Push the Injection Rate Comparison Meter Kit - Remote Cable VAG1348/3A.

NOTE:

The Transfer Fuel Pump -G6- is activated!

-- Adjust the pressure to 4.0 bar with the adjustment wheel on the Pressure Tester Kit - Pressure Regulator Valve VAS6550/4 -arrow-.

Fig 12: Pressure Setting Knob

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- From this point on do not move the pressure setting knob.

-- Empty measuring container.

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

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

Fig 13: Identifying Graph Of Voltage Versus Delivery Rate

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Axis designation	Unit
Minimum delivery rate	cm³
Fuel pump voltage when the engine is idling and the pump is running	Volt

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 the specification is not obtained:

-- Remove the fuel delivery unit and check the filter screen for dirt, refer to Separating the Flange from the Fuel Delivery Unit .

-- Check the fuel lines for leaks and damage.

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

If no fault was detected:

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

If no faults were found while checking the current draw:

-- Replace the fuel delivery unit flange, refer to Separating the Flange from the Fuel Delivery Unit .

NOTE:

The pressure relief valve and the fuel filter are integrated in the fuel delivery unit flange and cannot be replaced separately.

-- Repeat the fuel delivery rate test at the fuel delivery unit.

If the specification is not obtained:

-- Replace the fuel delivery unit, refer to FUEL DELIVERY UNIT/FUEL LEVEL SENSOR .

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 fuel pump current draw, refer to CURRENT DRAW, CHECKING .