Checking fuel delivery rate, vehicles with fuel pump control unit J538 — VW

🧭 Before you start

Fits: platform codes 5C7, 5C1

• Special tools named: VAS 5565
• Renewed: fuel filter, fuel delivery unit

Don't miss

• This step serves only to have the fuel pump running when the engine is stopped.
• Ensure plug-in connectors are secured properly by pulling.
• Ensure that drain tap (C) on pressure tester(1) is closed.
• The fuel system pressurisation pump G6 will be actuated.

🔧 Engine codes this applies to

📐 46 workshop diagrams for CAVD

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. Remove rear bench seat General body repairs, interior72Rear seat; Removing and installing bench seat / individual seats.
2. Remove fuel pump control unit J538(2) from cover (1).
3. Unclip cover (1) at retaining tabs (arrows), using removal wedge3409.
4. Check that connector (arrow) is fitted securely by pulling connector without pressing catch.
5. Release and unplug connector (arrow).

6. Check contacts on plug and on fuel delivery unit for damage.
7. Connect test instrument adapter/DSO (5-pin)VAS 5565 to connector and fuel delivery unit.
8. Connect remote controlV.A.G 1348/3A to adapterVAS 5565 and to battery positive terminal in engine compartment. [Note: This step serves only to have the fuel pump running when the engine is stopped.]
9. The delivery rate of the fuel pump depends on the battery voltage. Therefore also connect multimeter to contacts (1) and (5) of adapterVAS 5565.
10. Pull off supply line (1). Separate plug-in connectors .
11. Collect escaping fuel with a cleaning cloth.
12. Connect hoseVAS 6550/2 to connection (A) of pressure testerVAS 6550.
13. Connect pressure control valveVAS 6550/4 to connection (B) of pressure testerVAS 6550.
14. Connect hoseVAS 6550/2 to fuel line from fuel tank.
15. Hold end of hose of pressure regulator valveVAS 6550/4 in measuring container.
16. Ensure plug-in connectors are secured properly by pulling.
17. Ensure that drain tap (C) on pressure tester(1) is closed.
18. Shut-off valves (A) and (B) on pressure tester(1) are open.
19. Press remote controlV.A.G 1348/3A. [Note: The fuel system pressurisation pump G6 will be actuated.]
20. Set pressure of 4.0 bar on pressure regulating valve(arrow) using adjuster wheel.
21. Keep the adjuster in this position from this point on.
22. Drain measuring container.
23. Press remote control for 60 seconds whilst measuring voltage at fuel pump.
24. Compare delivered quantity of fuel with specification indicated in chart.
25. Open tank flap unit.
26. Clean area around fuel filler neck.
27. Unscrew cap from fuel filler neck (arrow).
28. Repeat fuel delivery rate check .
29. Check fuel tank breather .
30. Check fuel lines for possible restrictions (kinks) or blockages.
31. Check fuel lines for leaks and damage.
32. Pull fuel supply line (arrow) off fuel filter. Separate plug-in connectors .
33. Connect hoseVAS 6550/1 to connection (A) of pressure testerVAS 6550.
34. Connect pressure regulator valveVAS 6550/4 to connection (B) of pressure testerVAS 6550
35. Connect pressure testerVAS 6550 to fuel supply line (2) by means of hoseVAS 6550/1.
36. Hold end of hose of pressure regulator valveVAS 6550/4 in measuring container.
37. Ensure that drain tap (C) on pressure tester(1) is closed.
38. Shut-off valves (A) and (B) on pressure tester(1) are open.
39. Press remote controlV.A.G 1348/3A. [Note: The fuel system pressurisation pump G6 will be actuated.]
40. Set pressure of 4.0 bar on pressure regulating valve(arrow) using adjuster wheel.
41. Keep the adjuster in this position from this point on.
42. Drain measuring container.
43. Press remote control for 60 seconds whilst measuring voltage at fuel pump.
44. Check fuel line leading to engine for possible restrictions (kinks) or blockages.
45. Check fuel line leading to engine for leaks and damage.
46. Renew fuel filter .
47. Pull fuel line (1) off flange. Separate plug-in connectors .
48. Connect hoseVAS 6550/2 to connection (A) of pressure testerVAS 6550.
49. Connect pressure regulator valveVAS 6550/4 to connection (B) of pressure testerVAS 6550
50. Connect pressure testerVAS 6550 to fuel delivery unit (1) using hoseVAS 6550/2.
51. Hold end of hose of pressure regulator valveVAS 6550/4 in measuring container.
52. Ensure that drain tap (C) on pressure tester(1) is closed.
53. Shut-off valves (A) and (B) on pressure tester(1) are open.
54. Press remote controlV.A.G 1348/3A. [Note: The fuel system pressurisation pump G6 will be actuated.]
55. Set pressure of 4.0 bar on pressure regulating valve(arrow) using adjuster wheel.
56. Keep the adjuster in this position from this point on.
57. Drain measuring container.
58. Press remote control for 60 seconds whilst measuring voltage at fuel pump.
59. Remove fuel delivery unit .
60. Check fuel lines for possible restrictions (kinks) or blockages.

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