Volkswagen Workshop Service and Repair Manuals

Special tools, testers and auxiliary items

• ◆ Pressure tester V.A.G 1318
• ◆ Adapter 1318/11
• ◆ Adapter 1318/23
• ◆ Adapter 1318/7
• ◆ Adapter 1318/14
• ◆ Torque wrench V.A.G 1783 (2...10 Nm)
• ◆ Torx-Bit set V.A.G 1766

Test conditions

• ● Fuel pump delivery rate OK, checking:

=> Repair group 20; Removing and installing parts of the fuel supply system; Checking fuel pump

Test sequence

Note:

Check whether a coded radio is installed as during the forthcoming work sequences the battery earth strap must be disconnected. Obtain radio code first if necessary.

Only for air cleaner on the injection unit (round air cleaner):

• ‒ Remove air cleaner.

• ‒ Connect pressure gauge V.A.G 1318 as follows between fuel supply pipe -1- and injection unit:

→ Banjo connection
     with adapters 1318/7, /14 and /23

→ Connect hose directly on connection
     with adapter 1318/11 and /23

• ‒ Open pressure gauge tap. The lever points in direction of flow.
• ‒ Start the engine and run at idling speed.

If the engine does not start:

• ‒ → Pull fuel pump relay (J17) out of relay plate (relay position 12).

Note:

If the relay cannot be removed from the relay plate without tools then first disconnect battery earth strap.

• ‒ Connect remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-2 to contact 4 and battery positive (+).

• ‒ Operate remote control.

• ‒ Check fuel pressure.
       Specification: Approx. 0.8...1.2 bar

If the specification is exceeded or not reached:

• ‒ Dismantle the pressure regulator as follows:

→ Engine code ABD

Note:

First remove the intake air temperature sender -8- and unclip the cable guide -6-.

→ Engine code ABU, AEA

• ‒ Clean the individual parts of the pressure regulator and the injection unit upper part.

Assembling

• ‒ Place the membrane -1- as shown in the injection unit upper part.
• ‒ Insert the spring -2- and compress it with the pressure regulator upper part -3-.
• ‒ Carefully tighten the retaining ring -4- with screws -5- (tightening torque: 1.5 Nm).

Engine code ABD only:

• ‒ Install the intake air temperature sender -8- and tighten screw -7- to
       5 Nm.
• ‒ Clip on the cable guide -6-.

• ‒ Repeat the pressure regulator test.

If the specification is again not reached:

• ‒ Replace injection unit upper part.

If the specification is again exceeded:

• ‒ Check return pipe for blockage. If no fault is found, replace the injection unit upper part.
• ‒ Switch off ignition or remote control and check holding pressure.
       Specification:
       at least 0.5 bar after 5 minutes.

If the holding pressure drops below specification:

• ‒ Check pipe connections, O rings on injector and injector for leaks.
• ‒ Check fuel pump non-return valve.

=> Repair group 20; Removing and installing parts of the fuel supply system; Checking fuel pump

If the pressure drops again:

• ‒ Renew injection unit upper part.

Note:

The injection unit upper part and components of the fuel pressure regulator are matched to one another. Therefore individual parts of the pressure regulator must not be exchanged. It is only permissible to dismantle the pressure regulator for cleaning. If the pressure regulator is defective the complete injection unit upper part must be replaced.