Volkswagen Golf Service & Repair Manual: Checking operation and power supply of fuel pump
| Special tools and workshop equipment
required |
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| Multimeter e.g. hand-held multimeter -V.A.G 1526E- |
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| Auxiliary measuring set -V.A.G 1594C- |
| Vehicle diagnostic tester |
| 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. |
 Note
| Function of fuel pump is checked using final control
diagnosis. |
| – |
Observe safety precautions
→ Chapter. |
| – |
Observe rules for cleanliness
→ Chapter. |
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Connect vehicle diagnostic tester-1-
as follows: |
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Connect diagnosis cable connector -2-
to diagnostic connection in driver footwell. |
| – |
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. |
| If fuel pump does not run: |
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| – |
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-. |
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Remove rear bench seat
→ General body repairs, interior; Rep. gr.72. |
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| Continuation for all vehicles: |
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Unclip cover -1- for flange on
right at retaining tabs -arrows-,
using removal wedge -3409-. |
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| – |
Unclip sealing grommet -1-
downwards from cover -2-. |
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Push cover -2- back along
wiring harness -3-. |
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| – |
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. |
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| – |
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. |
| 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. |
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| 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. |
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| 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. |
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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-. |
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| Continuation for all vehicles: |
| – |
Open locking ring using wrench -T10202-. |
| – |
Check that electrical wires between flange and fuel pump are
connected. |
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| – |
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. |
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Special tools and workshop equipment
required
Removal wedge -3409-
...
Other materials:
Overview of fitting locations – lights in roof trim
1 -
Driver side illuminated vanity mirror -W20-
In the case of vanity mirrors with LED lighting, the entire light
must be renewed in the event of a fault.
Removing and installing
→ Chapter
2 -
...
Declaration of conformity
First read and observe the introductory information
and safety warnings The individual manufacturer declares herewith that the
following products conform, at the time of vehicle production, with the basic requirements
and other relevant laws and regulations, including FCC Part 15.19, FCC Par ...
Contact surface cleaning set -VAS 6410-
Using contact surface cleaning set -VAS 6410-
The contact surface cleaning set -VAS 6410- allows optimal
repair quality to be achieved in the area of vehicle electrics.
The tools allow performing repair work in the area of the sensor
in wiring harnesses for t ...
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Fuel pump
Checking function and voltage supply of the fuel pump, engine code CWVA