4.2L

Fuel Pump Delivery Rate, Checking

Special tools, testers and auxiliary items required

• Fuel Inj. Pressure Gauge-CIS (V.A.G 1318)

• Adapter (V.A.G 1318/10)

• Adapter (V.A.G 1318/11)

• Remote Control (V.A.G 1348/3A) with Remote Control for VAG1348 (V.A.G 1348/3-3)

• Connector Test Set (V.A.G 1594C)

• Measuring container, fuel-resistant

Procedure






• Fuse for Fuel Pump (FP) control module (J538) OK.

• Battery voltage at least 12.5 V.

• FP control module OK; check in Guided Fault Finding using a vehicle diagnostic tester.

• Fuel filter OK.

• Fuel tank minimum 1/4 full.

• Ignition switched off

Vehicles through 10.2006:






• FP control module is located at front of fuel tank below exhaust system and driveshaft.

Danger of getting burned.

• Allow exhaust system to cool.

- Disconnect electrical connector - 2 -.

• Ignore - 1 and 3 - and - arrow -.

Vehicles from 11.2006:

• The FP control module is located on the right side under the rear seat bench, directly under the floor covering.

- Remove right seat frame in 2nd row.






Risk of injury.

• Wear safety gloves.

- Cut the floor covering along the perforation - arrows - on the right side with a carpet knife - 1 -.

- Press the floor covering to the side and disconnect the connector - 1 -.






• Ignore - arrows -.

All Vehicles:






- Connect connector terminal - 2 - with an adapter cable from (V.A.G 1594C) to chassis Ground (GND).

- Connect (V.A.G 1348/3A) with (V.A.G 1348/3-3) to terminal - 1 - on connector.

- Cover the second connector terminal of (V.A.G 1348/3-3) with insulating tape to prevent short circuit - arrow -.

- Route (V.A.G 1348/3A) switch forward in the engine compartment.

- Release the retaining clip and open the cover - A - over the positive terminal clamp.

- Connect the alligator clip to the positive terminal clamp.

- Remove the fuel cap from the fuel filler tube.

- Pull the rear engine cover off - arrows -.






Risk of injury from fuel.

• To reduce residual pressure remaining in fuel system, lay a clean cloth around the connector and carefully loosen connector.

- Disconnect fuel supply line - 3 - and the distribution piece.






• Ignore - 1 and 2 -.

- Connect (V.A.G 1318) with (V.A.G 1318/10) and (V.A.G 1318/11) in fuel line.






- Connect an assisting hose - arrow - to pressure gauge and hold it in a measuring container.

- Open shut-off valve of pressure gauge.

• The lever points in the direction of flow.

- Generate pressure in the fuel system by pressing the switch of the remote control and slowly closing the shut-off valve of the pressure gauge.

• Specified value: 4 bar positive pressure.

- From this point on do not move position of shut-off valve.

- Empty the measuring container.

- Press the switch on the remote control for 15 seconds.






- Compare quantity of fuel delivered with minimum delivery rate in diagram (cm3/15s).

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

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

• Fuel lines pinched.

• Fuel filter clogged.

• Fuel pump faulty.

Assemble in reverse order of disassembling. Note the following:

• Secure all hose connections with hose clamps of the same type as those equipped by the factory. Refer to the Electronic Parts Catalog (ETKA).

Vehicles from 11.2006:

- Install the frame into the floor covering. and to the Electronic Parts Catalog (ETKA)

- Install right seat frame in 2nd row.