Volkswagen Workshop Service and Repair Manuals

Checking voltage supply

• ◆ Battery voltage ok.
• ◆ Fuse OK.
  ▸7/82 Fuse and fuel pump relay -J17-
  8/82 ▸ Fuse No. 5.

• ‒ Remove high tension wire from coil at the distributor and connect to earth using the adapter wire from V.A.G. 1594.
• ‒ Operate starter briefly.
• ‒ The fuel pump should be heard running.
  Should the pump fail to begin operating:
• ‒ Connect remote control V.A.G 1348/3A .
• ‒ Press remote control switch.

Fuel pump(s) run:

• ‒ Check fuel pump relay => page 20-41 .

Fuel pump(s) fails to run/only one pump runs:

• ‒ Check the voltage supply at the pump using LED Test Lamp V.A.G 1527 and the adapter wire from V.A.G 1594.

a) Fuel lift pump: 2/84 ▸

(located in fuel tank)

• ‒ → Remove connector at fuel level sender unit and use adapter wires to connect the LED Test Lamp to the middle and outer brown wires.

• ‒ Press remote control switch. The LED should light up. Where necessary, use the CDF to locate and repair open circuit.
• ‒ If the voltage supply is OK, renew lift pump => page 20-48 .

b) Fuel pump

(installation position: underside of vehicle just forward of right side rear axle mount)

• ‒ → Remove electric wires from fuel pump and connect LED Test Lamp to these using adapter wires.
• ‒ Press the remote control switch. LED should light up. Where indicated, locate the open circuit using Current Flow Diagram and repair.
• ‒ If voltage supply is Ok, renew fuel pump.

Checking delivery capacity

• ◆ Voltage supply OK.
• ◆ V.A.G 1384/3A remote control connected => page 20-23 .

• ‒ Remove cap from filler neck.

Fuel lift pump: 2/84 ▸

• ‒ Remove rear seat. Remove cover.

• ‒ → Remove supply pipe -1- (black) and seal it off.
• ‒ Attach a hose max. 350 mm in lenght to free connection on sender.
• ‒ Place the hose in a measuring glass and activate the remote control for 10 seconds.

• Quantity pumped: at least 300 cm3

Fuel pump

• ◆ Lift pump OK (2/84 ▸)

• ‒ → Remove fuel return pipe at the connection and hold it a measuring glass
• ‒ Pres the remote control switch for 30 seconds

• ‒ → Compare quantity delivered with specification => diagram.

     *)     Minimum delivery cm3/30 seconds

     **)     Voltage at fuel pump with engine stationary and pump running (approx. 2 volts less than battery voltage).

Note:

Should the minimum quantity not be achieved:

• ◆ Renew fuel filter (clogged).
• ◆ Fuel resorvoir with strainer (on tank) clogged (2/84 ▸).
• ◆ Renew fuel pump.