Volkswagen Golf Service & Repair Manual: Checking operation and power supply of fuel pump

Volkswagen Golf Service & Repair Manual / Fuel supply system - Petrol engines / Fuel supply, gas operation / Fuel pump / Checking operation and power supply of fuel pump

Special tools and workshop equipment required

Removal wedge -3409-

Checking operation and power supply of fuel pump

Multimeter e.g. hand-held multimeter -V.A.G 1526E-

Checking operation and power supply of fuel pump

Auxiliary measuring set -V.A.G 1594C-

Vehicle diagnostic tester

Test prerequisites

Battery voltage must be at least 11.5 V. If necessary, charge battery → Electrical system; Rep. gr.27.

Fuse for fuel pump control unit -J538- OK → Current flow diagrams, Electrical fault finding and Fitting locations.

Fuel pump control unit -J538- OK → Vehicle diagnostic tester.

Test sequence:

Note

Function of fuel pump is checked using final control diagnosis.

–	Observe safety precautions → Chapter.

–	Observe rules for cleanliness → Chapter.

Checking operation and power supply of fuel pump

–	Connect vehicle diagnostic tester-1- as follows:

–	Connect diagnosis cable connector -2- to diagnostic connection in driver footwell.

–	Switch ignition on.

–	Select final control diagnosis for fuel pump in vehicle self-diagnosis program.

The fuel pump must now run slowly up to maximum speed.

Note

The fuel pump runs very quietly.

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.

–	Switch off ignition.

If fuel pump does not run:

Checking operation and power supply of fuel pump

Golf SV:

–	Remove right rear seat → General body repairs, interior; Rep. gr.72.

–	Partially detach cover -1- in floor covering at parting line -arrow-.

–	Do not detach cover completely from floor covering in order to ensure it is reinstalled in the correct installation position.

–	Detach it just enough that the cover can be folded upwards.

–	Fold up cover in -direction of arrow-.

Golf and Golf Estate:

–	Remove rear bench seat → General body repairs, interior; Rep. gr.72.

Checking operation and power supply of fuel pump

Continuation for all vehicles:

–	Unclip cover -1- for flange on right at retaining tabs -arrows-, using removal wedge -3409-.

Checking operation and power supply of fuel pump

–	Unclip sealing grommet -1- downwards from cover -2-.

–	Push cover -2- back along wiring harness -3-.

Checking operation and power supply of fuel pump

–	Press up tab -2- in -direction of arrow A-; to do so, reach between floor panel and fuel tank with your finger.

–	At the same time, carefully pull fuel pump control unit -J538--1- out of mounting -in direction of arrow B- by grasping hold of wiring harness -3-.

–	Guide fuel pump control unit -J538- out towards interior between fuel tank and floor panel.

–	Ensure that connector on fuel pump control unit -J538- is fitted securely by pulling connector without pressing catch. If connector was not inserted correctly, repeat functional check of fuel pump.

–	Release and pull off connector from fuel pump control unit -J538-.

–	Check contacts on connector and on fuel pump control unit -J538- for damage.

Checking operation and power supply of fuel pump

–	Check voltage supply between contacts -3- and -4- using multimeter → Current flow diagrams, Electrical fault finding and Fitting locations.

–	Use auxiliary measuring set -V.A.G 1594C- to do this.

–	Switch ignition on.

Specification: approx. battery voltage

If the specification is not attained:

–	Locate and eliminate open circuit referring to current flow diagram → Current flow diagrams, Electrical fault finding and Fitting locations.

Checking operation and power supply of fuel pump

If specification is attained on vehicles with front-wheel drive:

–	Check that connector -1- is fitted securely by pulling connector without pressing catch. If connector was not inserted correctly, repeat functional check of fuel pump.

–	Release and pull off connector -1-.

–	Check contacts on plug and on fuel delivery unit for damage.

–	Check wiring harness between fuel pump control unit -J538- and fuel delivery unit → Current flow diagrams, Electrical fault finding and Fitting locations.

Checking operation and power supply of fuel pump

If specification is attained on vehicles with four-wheel drive:

–	Check that connector -1- is fitted securely by pulling connector without pressing catch. If connector was not inserted correctly, repeat functional check of fuel pump.

–	Release and pull off connector -1-.

–	Check contacts on plug and on fuel delivery unit for damage.

–	Check wiring harness between fuel pump control unit -J538- and fuel delivery unit → Current flow diagrams, Electrical fault finding and Fitting locations.

Checking operation and power supply of fuel pump

If no fault is detected:

The fuel system is pressurised.Risk of injury due to fuel which may spurt out.Wear eye protection.Wear protective gloves.Release pressure: place clean cloth around connection and carefully open connection.

–	Draining fuel tank → Chapter

–	Pull fuel line -1- off flange. Separate plug-in connectors → Chapter.

Vehicles with auxiliary heater:

–	Remove fuel line -2- leading to metering pump -V54- for auxiliary heater from sealing flange.

–	To do this, open clip at bottom.

–	Carefully pull out fuel line -2-.

Checking operation and power supply of fuel pump

Continuation for all vehicles:

–	Open locking ring using wrench -T10202-.

–	Check that electrical wires between flange and fuel pump are connected.

Checking operation and power supply of fuel pump

–	Check electrical wiring between flange and fuel pump for continuity using an ohmmeter.

–	Check contacts for damage.

If no open circuit can be found:

–	Fuel pump is defective, renew fuel delivery unit → Chapter.

Checking operation and power supply of fuel pump

Fuel pump

...

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