Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 756
– 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 -
VAS6550- -1- are opened.
– 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: 4.0 to 7.0 bar.
If the fuel pressure is OK, check the residual pressure. Refer to
⇒ “8.1.5 Residual Pressure, Checking”, page 95
If the specified value is exceeded:
– The pressure relief 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
.
If the specified value is not obtained:
Proceed as follows to check the fuel pressure at the fuel delivery
unit:
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 -3409- .
– Unclip the grommet -1- downward out of the cover -2-.
– Guide the cover -2- on the wiring harness -3- toward the rear.
– Lift the tab -2- in the direction of the -arrow A- by using a finger
to reach between the floor panel and the fuel tank.
– At the same time, pull the Fuel Pump Control Module -1- on
the wiring harness -3- in the direction of the -arrow B- carefully
out of the mount.
– Remove the Fuel Pump Control Module - J538- toward the
inside between the fuel tank and the floor panel.
– Move the Fuel Pump Control Module - J538- to the side with
the connector connected.
– Remove the fuel lines -1- from the flange. Disconnect the con‐
nector 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 -VAS6550- to the fuel delivery unit -1- using the
-VAS6550/3-4- .
– Connect the -VAS6550/3-3- between the -VAS6550- and the
fuel supply 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 -VAS6550- -1- are
opened.
– Repeat the output diagnostic test mode to build up the fuel
pressure again.
If the specified value is obtained:
– Check the fuel lines for possible restrictions (kinks) or block‐
ages.
– Check the fuel line for leaks and damage.
If the specified value is not obtained:
– Remove the fuel delivery unit (refer to
⇒ “2.2 Fuel Delivery Unit/Fuel Level Sensor, Removing and
) and inspect it for debris.
– Make sure all hoses -arrows- are connected.
– Check the fuel lines for possible restrictions (kinks) or block‐
ages.
– Check the fuel lines for leaks and damage.
If no error can be found:
– If the fuel pump is faulty, replace the fuel delivery unit. Refer
to
⇒ “2.2 Fuel Delivery Unit/Fuel Level Sensor, Removing and
.
8.1.4
Fuel Pressure, Checking, Vehicles with
Engine Code CWVA
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-
♦ Vehicle Diagnostic Tester
Conditions:
• Power supply is OK.
⇒ “8.1.1 Fuel Pumps, Checking Function and Power Supply”,
.
– Pay attention to all safety precautions. Refer to
⇒ “1 Safety Precautions”, page 1
– Follow the guidelines for clean working conditions. Refer to
⇒ “3.1 Parking/Auxiliary Heater and Fuel System Clean Work‐
.
– Remove the supply line -1-. Disconnect the connector cou‐
plings. 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.
– Collect leaking fuel with a cleaning cloth.
– Connect the -VAS6550/1- to the connection -A- on the -
VAS6550- .
– Connect the -VAS6550/1- to the fuel supply line -1- to the en‐
gine.
– Connect the -VAS6550/2- to the connection -B- on the -
VAS6550- .
– Connect the fuel line to the fuel tank with the -VAS6550- via
the -VAS6550/2- .
– Pull on the connector couplings to check them for secure fit.
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