Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 759
– Connect the Pressure Tester Kit - Hose 2 - VAS6550/2- be‐
tween the fuel line from the fuel tank and the shut-off valve
-B- on the Pressure Tester Kit - VAS6550- .
– Connect the Pressure Tester Kit - Hose 1 - VAS6550/1- be‐
tween the fuel line leading to the engine -1- and the shut-off
valve -A- on the Pressure Tester Kit - VAS6550- .
Test sequence:
– Connect the Vehicle Diagnostic Tester .
– Select the fuel pump output diagnostic test mode in OBD.
Note
♦
The fuel pump is now activated to build up the fuel pressure.
♦
If the output diagnostic test mode is performed several times
in succession, it may be necessary to briefly start the motor
before repeating the output diagnostic test mode.
– Read the fuel pressure on the pressure gauge.
• Specified value: greater than or equal to 4.0 bar
– End the OBD and turn off the ignition.
– Observe the decrease in pressure on the pressure gauge. Af‐
ter 10 minutes the pressure must not drop more than approx‐
imately 1 bar.
If the pressure drops:
– Check all of the fuel lines for leaks and damage.
If no faults can be found:
– Make sure that the drain valve -C- on the Pressure Tester
-1- is closed.
– The shut-off valves -A- and -B- on the Pressure Tester Kit
-1- are opened.
– Activate the fuel pump using the output diagnostic test mode
to build the fuel pressure.
– Close the shut-off valve -A- on the pressure gauge immedi‐
ately after the pressure has been reached. The lever is per‐
pendicular to the flow direction.
If the pressure drops again (Leak on fuel tank side):
Proceed as follows to check residual pressure on the fuel delivery
unit. Refer to
.
If the pressure now stops decreasing (leak on the engine side):
Note
Check for the leak on the engine-side. Repeat the residual pres‐
sure check. Close the shut-off valve -B- this time to determine if
there actually is a leak on the engine side.
If there is a leak on the engine side:
– Check the fuel lines externally for leaks.
– Check the fuel rail and the fuel injectors externally for leaks.
Refer to ⇒ Rep. Gr. 24 ; Fuel Injectors; Overview - Fuel Rail
with Fuel Injectors .
If no error can be found:
– Check the fuel injectors for leaks. Refer to ⇒ Rep. Gr. 24 ;
Fuel Injector; Fuel Injectors, Checking .
Residual Pressure in Fuel Delivery Unit, Checking:
Golf Sportsvan:
– Remove the right rear seat. Refer to ⇒ Body Interior; Rep. Gr.
72 ; Rear Seats; Bench Seat / Single Seat, Removing and In‐
stalling .
– Partially loosen the cover -1- in the carpet at the separating
line -arrow-.
– Do not separate the cover completely from the carpet so that
later it will be installed correctly.
– Only loosen so far that the cover can be folded up.
– Fold up the cover in the -direction of the arrow-.
Golf and Golf wagon:
– Remove the rear bench seat. Refer to ⇒ Body Interior; Rep.
Gr. 72 ; Rear Seats; Bench Seat / Single Seats, Removing
and Installing .
Continuation for All Vehicles:
– Unclip the sealing flange cover -1- at the tabs -arrows- using
the Trim Removal Wedge - 3409- .
– Unclip the grommet -1- downward out of the cover -2-.
– Guide the cover -2- on the wiring harness -3- toward the rear.
– Pull the fuel line -1- off the flange. Disconnect the connector
couplings. Refer to
⇒ “4.1 Connector Couplings, Disconnecting”, page 62
WARNING
The fuel line is under pressure.
Fuel poses a risk of injury to the eyes and skin.
Wear protective eyewear and protective clothing to avoid injury
and contact with skin. Place a cleaning cloth around the con‐
nection point before loosening hose connections. Carefully
open the connection point to release the pressure.
– Connect the Pressure Tester Kit - VAS6550- to the fuel deliv‐
ery unit -1- using the Pressure Tester Kit - Adapter Set - Hose
4 - VAS6550/3-4- .
– Connect the Pressure Tester Kit - Adapter Set - Hose 3 -
VAS6550/3-3- between the Pressure Tester Kit - VAS6550-
and the fuel line -2-.
– Pull on the connector couplings to check them for secure fit.
– Make sure that the drain valve -C- on the Pressure Tester
-1- is closed.
– The shut-off valves -A- and -B- on the Pressure Tester Kit
-1- are opened.
– Activate the fuel pump using the output diagnostic test mode
to build the fuel pressure.
– Close the shut-off valve -B- on the pressure gauge immedi‐
ately after the pressure has been reached. The lever is per‐
pendicular to the flow direction.
– Repeat the residual pressure check. Refer to
.
If the pressure no longer decreases:
– Check the fuel line for leaks.
If the pressure drops again:
– Open the fuel delivery unit -1-. Refer to
⇒ “2.2 Fuel Delivery Unit/Fuel Level Sensor, Removing and
– Make sure all hose connections -arrows- are connected.
– Check the fuel lines for leaks and damage.
If no error can be found:
– If the pressure retaining valve in the fuel delivery unit is faulty,
replace the fuel delivery unit. Refer to
⇒ “2.2 Fuel Delivery Unit/Fuel Level Sensor, Removing and
8.1.7
Fuel Delivery Rate, Checking
Special tools and workshop equipment required
♦ Trim Removal Wedge - 3409-
♦ Pressure Tester Kit - VAS6550-
♦ Pressure Tester Kit - Adapter Set - Hose 3 - VAS6550/3-3-
♦ Pressure Tester Kit - Adapter Set - Hose 4 - VAS6550/3-4-
♦ Pressure Regulator Valve - VAS6550/4-
♦ Connector Test Set - VAG1594D-
♦ Multimeter, for example Analog/Digital Multimeter - FLU83III-
♦ Injection Rate Comparison Meter Kit - Remote Cable -
VAG1348/3A-
♦ Vehicle Diagnostic Tester - Test Adapter - 5 Pin - VAS5565-
♦ Vehicle Diagnostic Tester
♦ Measuring container, greater than three liters
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