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Generic Scan Tool - Fuel Supply



Fuel Pump, Checking







Recommended special tools and equipment
- VAG1318 pressure gauge
- VAG1598/1 adapter
- VAG1598/11 adapter
- V.A.G 1318/16 hose adapter
- VAG 1598/17 adapter
- Double connection V.A.G 1318/23







- T10202 wrench
- VAG1348/3A remote control connection
- VAG 1594 C connector test kit
- VAG 1715 multimeter
- Torque wrench (40 to 200 Nm) VAG 1332

without illustration:
- Measuring container
- Wiring diagram
- Protective glasses

Test requirements
- Fuel Pump (FP) Control Module -J538- must be OK, check. Testing and Inspection
- Low Fuel Pressure Sensor -G410- must be OK, checking.
- Battery voltage must be at least 11.5 Volts.
- All electrical consumers such as, lights and rear window defroster must be switched off.
- For vehicles with automatic transmission, selector lever must be in -P-.
- Ignition switched off.

NOTE: Note function description of crash fuel shut-off.

Checking function and voltage supply
Observe safety precautions.
Observe rules for cleanliness.

- Remove seat bench.







- Disconnect 10-pin connector from Fuel Pump (FP) Control Module -J538- -2- and remove cover -1- with Fuel Pump (FP) Control Module -J538-.







- Disconnect 5-pin connector -A- from flange.







- Connect remote control connection V.A.G 1348/3A using adapter cable to terminal 1 (+) to flange of Fuel Pump (FP) and to terminal 1 (+) of 10-pin connector.
- Connect terminals 6 (-) of 10-pin connector and terminal 5 (-) of flange to Fuel Pump (FP) using corresponding adapter cables.







- Terminal assignment of 10-pin connector for Fuel Pump (FP) Control Module -J538-
- Operate remote control.

Fuel Pump (FP) must run.
If Fuel Pump (FP) does not start up:







- Disconnect fuel line -B- from flange.

WARNING:
- The fuel or fuel lines in fuel system can become very hot (danger of scalding).
- In addition, the fuel system is under pressure. Before loosening hose connections or separating points, place rags around the connection point. Then release pressure by carefully opening the fuel supply system.
- Wear protective goggles and protective gloves when working on the fuel system.

NOTE: Press in securing ring to disengage the fuel line.

- Seal off line so that no dirt will get into fuel system.







- Remove seal of flange using T10202 wrench.
- Check whether electrical wires between flange and Fuel Pump (FP) are connected.

If there are no open circuits:
- Fuel Pump (FP) faulty, replace Fuel Pump (FP) unit.
- Erase DTC memory of Engine Control Module (ECM). Diagnostic Mode 04 - Erase DTC Memory
- Generate readiness code. Monitors, Trips, Drive Cycles and Readiness Codes

Checking fuel pressure
Observe safety precautions.
Observe rules for cleanliness.

WARNING:
- The fuel or fuel lines in fuel system can become very hot (danger of scalding).
- In addition, the fuel system is under pressure. Before loosening hose connections or separating points, place rags around the connection point. Then release pressure by carefully opening the fuel supply system.
- Wear protective goggles and protective gloves when working on the fuel system.







- Disconnect fuel supply line -arrow- and catch escaping fuel using a rag.

NOTE: Press in securing ring to disengage the fuel line.







- Connect pressure gauge (VAG1318) to adapters (VAG1318/1 and VAG1318/17) in place of fuel supply line.
- Open shut-off valve of pressure gauge. Lever will point in direction of flow -A-
- Remove seat bench.







- Disconnect 10-pin connector from Fuel Pump (FP) Control Module -J538- -2- and remove cover -1- with Fuel Pump (FP) Control Module -J538-.







- Disconnect 5-pin connector -A- from flange.







- Connect remote control connection V.A.G 1348/3A using adapter cable to terminal 1 (+) to flange of Fuel Pump (FP) and to terminal 1 (+) of 10-pin connector.
- Connect terminals 6 (-) of 10-pin connector and terminal 5 (-) of flange to Fuel Pump (FP) using corresponding adapter cables.







- Terminal assignment of 10-pin connector for Fuel Pump (FP) Control Module -J538-
- Operate remote control connection and check fuel pressure on pressure gauge.

Fuel pressure must increase up to a maximum pressure of 6.0 bar.

NOTE: If remote control connection is no longer activated, fuel pressure sinks to approx. 5.6 bar.

If fuel pressure is OK, check residual pressure.

If fuel pressure is exceeded:
- Pressure relief valve in flange malfunctioning. Replace flange with fuel filter.
- Erase DTC memory of Engine Control Module (ECM). Diagnostic Mode 04 - Erase DTC Memory
- Generate readiness code. Monitors, Trips, Drive Cycles and Readiness Codes

If fuel pressure is not reached:
- Check fuel lines for restrictions (kinks) or clogging.
- Erase DTC memory of Engine Control Module (ECM). Diagnostic Mode 04 - Erase DTC Memory
- Generate readiness code. Monitors, Trips, Drive Cycles and Readiness Codes

If no malfunctions are found in wires:
- Replace flange with fuel filter and pressure relief valve.
- Repeat test of fuel pressure.

If fuel pressure is not reached again:
- Fuel Pump (FP) faulty, replace Fuel Pump (FP) unit.
- Erase DTC memory of Engine Control Module (ECM). Diagnostic Mode 04 - Erase DTC Memory
- Generate readiness code. Monitors, Trips, Drive Cycles and Readiness Codes

Checking residual pressure

Test requirements
- Pressure gauge and remote control connection are still connected.
- Fuel pressure must be OK (fuel pressure on pressure gauge approx. 5.6 bar), checking.

Test sequence
- Observe pressure drop on pressure gauge. After 10 minutes, pressure must not fall below 4.0 bar within 10 minutes.

If pressure drops further:
- Operate remote control connection and check fuel pressure on pressure gauge.

Fuel pressure must increase up to a maximum pressure of 6.0 bar.







- Close shut-off valve of pressure gauge immediately after operating remote control connection. Lever will then point in position -B-.

NOTE: If remote control connection is no longer activated, fuel pressure sinks to approx. 5.6 bar.

- Observe pressure drop on pressure gauge. After 10 minutes, pressure must not fall below 4.0 bar within 10 minutes.

If pressure drops further:
(Leak on engine side)
- Check fuel line to high pressure pump for proper seal.
- Erase DTC memory of Engine Control Module (ECM). Diagnostic Mode 04 - Erase DTC Memory
- Generate readiness code. Monitors, Trips, Drive Cycles and Readiness Codes

If no malfunction can be found:
- Replace high pressure pump.
- Erase DTC memory of Engine Control Module (ECM). Diagnostic Mode 04 - Erase DTC Memory
- Generate readiness code. Monitors, Trips, Drive Cycles and Readiness Codes

If pressure no longer drops now:
(Leak on fuel tank side)
- Check supply line to flange for proper seal.
- Erase DTC memory of Engine Control Module (ECM). Diagnostic Mode 04 - Erase DTC Memory
- Generate readiness code. Monitors, Trips, Drive Cycles and Readiness Codes

If no malfunctions are found on supply line:
- Check-valve in flange malfunctioning. Replace flange with fuel filter.
- Erase DTC memory of Engine Control Module (ECM). Diagnostic Mode 04 - Erase DTC Memory
- Generate readiness code. Monitors, Trips, Drive Cycles and Readiness Codes

Checking fuel delivery
Observe safety precautions.
Observe rules for cleanliness.

- Remove seat bench.







- Disconnect 10-pin connector from Fuel Pump (FP) Control Module -J538- -2- and remove cover -1- with Fuel Pump (FP) Control Module -J538-.







- Disconnect 5-pin connector -A- from flange.







- Connect remote control connection V.A.G 1348/3A using adapter cable to terminal 1 (+) to flange of Fuel Pump (FP) and to terminal 1 (+) of 10-pin connector.
- Connect terminals 6 (-) of 10-pin connector and terminal 5 (-) of flange to Fuel Pump (FP) using corresponding adapter cables.







- Terminal assignment of 10-pin connector for Fuel Pump (FP) Control Module -J538-
- Remove fuel filler cap from fuel filler tube.

WARNING:
- The fuel or fuel lines in fuel system can become very hot (danger of scalding).
- In addition, the fuel system is under pressure. Before loosening hose connections or separating points, place rags around the connection point. Then release pressure by carefully opening the fuel supply system.
- Wear protective goggles and protective gloves when working on the fuel system.







- Disconnect fuel supply line -arrow- and catch escaping fuel using a rag.

NOTE: Press in securing ring to disengage the fuel line.







- Connect pressure gauge (V.A.G 1318) to fuel supply line using double connection (V.A.G 1318/23) and adapter (V.A.G 1318/17).
- Connect hose adapter (VAG1318/16) to adapter (VAG1318/11) of pressure gauge and hold into measuring container.

WARNING: Danger of spray when opening shut-off valve. Hold container in front of open connection on pressure gauge.

- Open shut-off valve of pressure gauge. Lever will point in direction of flow -A-.
- Operate remote control. Slowly close shut-off valve until pressure gauge displays 4 bar positive pressure is indicated. Do not change position of shut-off valve any more.
- Empty measuring container.
- Delivery rate of Fuel Pump (FP) is dependent on battery voltage. Therefore, connect multimeter to Fuel Pump (FP) using adapter cables.
- Operate remote control for 30 seconds and simultaneously measure voltage at Fuel Pump (FP).







- Compare fuel quantity pumped with specified value.
*) Minimum delivery rate cu.cm/30 s
**) Voltage at Fuel Pump (FP) with engine at stand still and pump running.

Read-out example:
During test, a voltage of 10.5 Volts is measured. This results in a minimum delivery rate of 580 cu.cm/30 s.

If minimum delivery rate is not obtained:
- Check fuel lines for restrictions (kinks) or clogging.

If no malfunctions are found in wires:
- Remove fuel delivery unit and check filter strainer for dirt.

If no malfunction is present here as well:
- Replace flange with fuel filter and pressure relief valve.
- Repeat test of delivery quantity.

If minimum delivery rate is still not obtained:
- Fuel Pump (FP) faulty, replace Fuel Pump (FP) unit.
- Erase DTC memory of Engine Control Module (ECM). Diagnostic Mode 04 - Erase DTC Memory
- Generate readiness code. Monitors, Trips, Drive Cycles and Readiness Codes

Delivery rate has been obtained, but malfunctions are still suspected in the fuel supply (e.g. sporadic loss of fuel supply):
- Reconnect all disconnected fuel lines and harness connectors.
- Check current pick-up of Fuel Pump (FP).

Current pick-up of Fuel Pump (FP), checking
Observe safety precautions.
Observe rules for cleanliness.

- Remove seat bench.







- Remove cover -1 with Fuel Pump (FP) Control Module -J538- -2- from fuel delivery unit.







- Connect multimeter with electrical current probe to wire of 5-pin connector terminal 1 arrow- from wiring harness.
- Start engine and let it run at idle.
- Measure Fuel Pump (FP) current draw.

Specified value: max. 9 amperes

NOTE: If disturbance in fuel system is sporadic, test can also be performed during a road test, but a 2nd person is required.

If current draw is exceeded:
- Fuel Pump (FP) faulty, replace Fuel Pump (FP) unit.
- Erase DTC memory of Engine Control Module (ECM). Diagnostic Mode 04 - Erase DTC Memory
- Generate readiness code. Monitors, Trips, Drive Cycles and Readiness Codes
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