Fuel Pump Delivery Quantity, Checking

WARNING: This page is about a different car, the 2009 Audi A4, 2008 Audi A4, 2007 Audi A4, 2006 Audi A4, and 2005 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Special tools, testers and auxiliary items required

Hand held remote control (jumper).
Multimeter.
Electrical connector test lead set.
Pressure gauge (High pressure)

Measuring container (fuel resistant).

Test conditions

Battery voltage at least 12.5 V.
The fuel filter OK
Fuse S228 OK.
Fuel Pump (FP) Control Module J538 OK → 20 - FUEL SUPPLY SYSTEM .

Fuel tank at least ¹ /₄ filled.
The ignition switched off.

Test sequence

Remove the rear seat bench →
- 72 - SEAT - FRAMES
- 72 - SEAT - FRAMES for BODY INTERIOR - CABRIOLET
.

Fig 1: Removing/Installing Cover Bolts For Locking Flange

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove the right locking flange cover and bolts - arrows -.

Fig 2: Disconnecting/Connecting Electrical Harness Connector At Right Locking Flange

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect the electrical harness connector - arrow - at the right locking flange.
Connect a Hand held remote control (jumper) to terminal - 1 - of the fuel delivery unit and to vehicle battery (+).

Fig 3: Connecting Other End Of Hand Held Remote Starter (Jumper) To Vehicle Battery (+)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Connect a jumper cable from a Electrical connector test lead set to terminal - 4 - of the fuel delivery unit and to vehicle Ground (GND).
Remove the fuel filler cap.

Fig 4: Removing/Installing Rear Engine Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove the rear engine cover - arrows -.

CAUTION: The fuel system is under pressure! Before opening system, place rags around the connection area. Then release pressure by carefully loosening the connection.

Fig 5: Disconnecting/Connecting Fuel Line

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect the fuel line - arrow -.
Connect a Pressure gauge (High pressure) to the fuel line.
Connect the extension hose - arrow - to the pressure gauge and hold it in a measuring container.
Open the pressure gauge shut-off valve. The lever points in the direction of flow.

Create fuel system pressure by pressing the switch on the Hand held remote control (jumper) in and slowly closing the shut-off valve of the pressure gauge.

Fig 6: Connecting Pressure Gauge V.A.G 1318 To Fuel Line Using Adapter V.A.G 1318/11 And V.A.G 1318/12

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pump the fuel

Specification: 4 bar positive pressure.

Do not move the position of the shut-off valve.
Empty the measuring container.

Fig 7: Delivery Rate Diagram

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press the switch on the Hand held remote control (jumper) in for 15 seconds.
Compare the quantity of fuel delivered with the minimum delivery rate in the diagram (cm ³ /15s).

NOTE:

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

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

Fuel lines pinched.
Fuel filter clogged.
Fuel pump faulty.

Installation

Fig 8: Disconnecting/Connecting Fuel Line

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Connect the fuel line - arrow -.

Fig 9: Removing/Installing Rear Engine Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install the rear engine cover - arrows -.

Fig 10: Disconnecting/Connecting Electrical Harness Connector At Right Locking Flange

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Connect the electrical harness connector - arrow - at the right locking flange.

Fig 11: Removing/Installing Cover Bolts For Locking Flange

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install the right locking flange cover and bolts - arrows -.
Install the rear seat bench →
- 72 - SEAT - FRAMES
- 72 - SEAT - FRAMES for BODY INTERIOR - CABRIOLET
.

Torque specifications

Component		Nm
Fuel line to fuel rail		22