Checking fuel pressure sender: VW 1.4 (CAVA, CAVB, CAVC, CAVD, …)

🧭 Before you start

Remove the engine cover and air filter and relieve the high-pressure side. Swap the sender for adapter VAS 6394/2 at 22 Nm, fit the sender into the gauge at 22 Nm and connect the pressure line hand-tight. Connect the test adapter and diagnostic tester, read the fuel pressure value with the engine running and compare with the gauge. If the values differ, renew the sender, compare again, then check the wiring.

Fits: VW Sharan II / SEAT Alhambra (7N, 2010–), VW Polo 6R (2009–2014), VW Touran I (1T, 2003–2015), VW Tiguan I (5N, 2007–2016), VW Passat CC (357, 2008–2012), VW Golf VI (5K, 2008–2013), VW Golf Cabriolet (517, 2011–2016), VW Passat B7 saloon (362, 2010–2014), VW Passat B7 Variant (365, 2010–2014); platform codes 5M1, 1F7, 137, 521

Don't miss

• Relieve the high-pressure side to approx. 6 bar before removing the sender.
• Open the system straight away after relieving; pressure rises again as the fuel warms.
• Moisten the adapter's tapered seal with clean engine oil before fitting it.
• Engine code CKMA uses measured value 140 rather than 248.
• Newer UDS control units need a different route to the measured value.

Written for this job from the workshop steps below · TorqFix editorial.

🔧 Engine codes this applies to

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. ⚠ The injection system consists of a high-pressure section (maximum approx. 120 bar) and a low-pressure section (approx. 6 bar).Prior to opening the high-pressure area, e.g. when removing the high-pressure pump, fuel rail, injectors, a fuel line, or the fuel pressure sender G247, the fuel pressure in the high-pressure area must be reduced to a residual pressure of approx. 6 bar. The appropriate procedure is described in the chapter on releasing pressure in the high-pressure section . — Lift engine cover panel at points (1) and pull it forwards in direction of (arrow).
2. Remove air filter .
3. Remove fuel pressure sender G247(1).
4. Instead of fuel pressure sender G247, screw in adapterVAS 6394/2 and tighten to 22 Nm. — 22 Nm (16 lb-ft)
5. Open cover (2) of digital pressure gaugeVAS 6394/1 and tighten fuel pressure sender G247 to digital pressure gauge to 22 Nm. — 22 Nm (16 lb-ft)

6. Screw pressure line (1) of digital pressure gaugeVAS 6394/1 hand-tight to adapterVAS 6394/2.
7. Connect test adapterVAS 5570 between fuel pressure sender G247(1) and connector.
8. Connect vehicle diagnosis, testing and information systemVAS 5051B(1) as follows:
9. Push diagnostic cable connector (2) onto diagnostic connection in driver footwell.
10. Switch on ignition.
11. Press following keys on display in succession:
12. Enter '248' (or '140' for engine code CKMA) and confirm with Q. [Note: A new generation of engine control units has been introduced (UDS => Unified-Diagnostic-Service). For these new-generation engine control units, a different procedure for requesting the required values applies.]
13. Press following keys on display in succession:
14. Confirm the test version and the model.
15. Allocate vehicle model.
16. Select model year.
17. Determine the engine version.
18. Specify "“engine”" as vehicle system to be used.
19. Follow the programmed steps of the tester until step »Select displayable measured values«.
20. Search for "“IDE00589 Fuel Pressure”" in the plain text.
21. Switch on digital pressure gaugeVAS 6394/1 by pressing key (A) briefly once. [Note: When button (A) is pressed for 2 seconds, the illumination will be switched on for 20 seconds.]
22. Start engine.
23. Compare pressure displayed by digital pressure gaugeVAS 6394/1 with actual value of vehicle diagnosis, testing and information systemVAS 5051B. [Note: Once the high-pressure in the high-pressure area is reduced, open the system immediately as the pressure will rise again due to warming.]
24. ⚠ The injection system consists of a high-pressure section (maximum approx. 120 bar) and a low-pressure section (approx. 6 bar).Prior to opening the high-pressure area, e.g. when removing the high-pressure pump, fuel rail, injectors, a fuel line, or the fuel pressure sender G247, the fuel pressure in the high-pressure area must be reduced to a residual pressure of approx. 6 bar. The appropriate procedure is described in the chapter on releasing pressure in the high-pressure section . — Renew fuel pressure sender G247 and again compare both measured values.
25. Check wiring .
26. Further testing is carried out with "“Guided Fault Finding”".

Other VW procedures

• Removing and installing radiator cowling · 1 torque figures
• Checking holding pressure, vehicles with fuel filter integrated into flange of fuel delivery unit
• Draining and filling coolant (Passat, Passat CC) – VW 1.4
• Removing and installing engine control unit with theft protection
• Removing and installing radiator with charge air cooler (Polo) · 1 torque figures
• Removing engine · 41 torque figures
• Removing and installing camshaft – VW Golf Cabriolet · 47 torque figures
• Adjusting valve timing – VW Passat B5 · 83 torque figures
• Removing and installing camshafts – VW Passat B6 · 39 torque figures
• Removing and installing coolant pump · 53 torque figures