CC 2010 β€ , Eos 2006 β€ , Golf 2004 β€ , Golf 2009 β€ , Passat 2006 β€ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
β If the sender cannot be released in this way, the retaining tabs
-arrows- must also be pushed to the side slightly.
β Note colour co-ordination of cables for reinstallation.
β Release electrical connectors -1 to 3- and pull them off. Then
bend back locking lugs of connectors.
Installing:
β Connect connectors -1β¦3-. Observe colour co-ordination.
β Check connectors are secured properly by pulling.
β Insert fuel gauge sender - G- into guide on fuel delivery unit
and press down until it engages.
β Install fuel delivery unit β page 346 .
8.3
Checking fuel pump - G6-
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Rep. gr.20 - Fuel supply system
CC 2010 β€ , Eos 2006 β€ , Golf 2004 β€ , Golf 2009 β€ , Passat 2006 β€ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
Special tools and workshop
equipment required
β¦ Pressure gauge - VAS 6550-
β¦ Remote control - V.A.G 1348/3A-
β¦ Test instrument adapter/DSO (5-pin) - VAS 5565-
β¦ Multimeter - V.A.G 1715-
β¦ Special wrench - T10202-
β¦ Torque wrench - V.A.G 1332-
β¦ Measuring container, capacity: 3 litres
8.3.1
Checking function and voltage supply
Test conditions:
β’
β’
β’
Battery voltage at least 11.5 V.
Fuse for Fuel pump control unit - J538- OK.
Fuel pump control unit - J538- OK.
8. Repairing fuel supply system (Golf, Eos, Scirocco)
351
CC 2010 β€ , Eos 2006 β€ , Golf 2004 β€ , Golf 2009 β€ , Passat 2006 β€ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
Test sequence
Note
β¦ Function of fuel pump is checked using final control diagnosis.
β¦ If the final control diagnosis is to be carried out several times
in succession, it may be necessary to start the engine briefly
before repeating the final control diagnosis.
β Connect vehicle diagnostic tester as follows:
β Push diagnosis cable connector onto diagnosis connection in
driver footwell.
β Switch ignition on.
β Press buttons on display one after the other for Vehicle
self-diagnosis, Engine electronics and Final con-
trol diagnosis.
β Press right arrow button βΊ on display up to final control diagβ
nosis for fuel pump electronics.
The fuel pump must now run slowly up to maximum speed.
Note
The fuel pump runs very quietly.
β Switch off ignition.
If fuel pump does not run:
β Remove bench seat β General body repairs, interior; Rep. gr.
72 ; Removing and installing bench seat .
β Pull connector off fuel pump control unit - J538- .
β Check voltage supply between contacts -1- and -6- using mulβ
timeter - V.A.G 1715- .
β’
Specification: approx. battery voltage
Voltage supply not OK:
β Locate and eliminate open circuit referring to current flow diβ
agram β Current flow diagrams, Electrical fault finding and
Fitting locations.
Voltage supply OK:
352
Rep. gr.20 - Fuel supply system
CC 2010 β€ , Eos 2006 β€ , Golf 2004 β€ , Golf 2009 β€ , Passat 2006 β€ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
β Remove cover -1- with fuel pump control unit - J538- -2- from
fuel delivery unit.
β First check that the connector -arrow- is fitted securely by pullβ
ing the connector without pressing the catch. If connector was
not inserted correctly, repeat functional check of fuel pump.
β Now pull off connector.
β Check the contacts on the connector and on the fuel delivery
unit for damage.
WARNING
Fuel supply line is pressurised. Wear protective goggles and
protective clothing to avoid injury and contact with the skin.
Wrap a cloth around the connection before loosening hose
connections. Then release pressure by carefully pulling hose
off connection.
β Pull fuel lines -1- and -2- off the flange.
Note
β¦ Press in securing ring to release the fuel lines.
β¦ On vehicles with auxiliary heater, the connector and the fuel
line of the metering pump - V54- must also be disconnected.
β Open locking ring using key - T10202- .
Caution
Do not cant key - T10202- and press against locking ring firmly.
If the key slips off, the fuel delivery unit can be damaged.
β Check that electrical wires between flange and fuel pump are
connected.
If no open circuit can be found:
β Fuel pump defective, renew fuel delivery unit β page 346 .
8. Repairing fuel supply system (Golf, Eos, Scirocco)
353
CC 2010 β€ , Eos 2006 β€ , Golf 2004 β€ , Golf 2009 β€ , Passat 2006 β€ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
8.3.2
Checking fuel pressure
Note
β¦ The fuel pressure must be checked by means of the final conβ
trol diagnosis. If the fuel pressure is measured at idling speed,
it may deviate from the specification.
β¦ If the final control diagnosis is to be carried out several times
in succession, it may be necessary to start the engine briefly
before repeating the final control diagnosis.
WARNING
Fuel supply line is pressurised. Wear protective goggles and
protective clothing to avoid injury and contact with the skin.
Wrap a cloth around the connection before loosening hose
connections. Then release pressure by carefully pulling hose
off connection.
β Pull off supply line (metal coupling) -arrow- and catch escaping
fuel with a cloth.
Note
Press in securing ring to release fuel line.
β Connect pressure tester - VAS 6550- to fuel supply line with
adapter - VAS 6550/1- and -VAS 6550/2- .
β Make sure that drain tap is closed and cut-off taps are open.
β Actuate fuel pump with final control diagnosis to build up fuel
pressure.
β Read fuel pressure on pressure gauge.
β’
Specification: 4.0 to 7.0 bar
If fuel pressure is OK, check holding pressure β page 358 .
If the specification is exceeded:
β Check return line between fuel filter and fuel pump for kinks
and blockages.
If no fault is found:
β Pressure limit valve in fuel filter is defective. Renew fuel filter.
If specification is not obtained
β Check fuel pressure upstream of fuel filter; proceed as follows:
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Rep. gr.20 - Fuel supply system