New Beetle Convertible L5-2.5L (BPR) (2007)
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Fuel Pump Relay: Testing and Inspection
Fuel Primer Relay J643, Checking
Special tools, testers and auxiliary items required
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Multimeter.
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wiring diagrams.
Test requirements
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Fuse SB42 OK.
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The Ground (GND) connections at the engine and transmission OK.
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The battery voltage at least 12.5 V.
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The generator OK.
Test procedure
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Perform a preliminary check to verify the customers complaint.
Start diagnosis
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Using a Multimeter, check the following wiring connection for voltage.
Fuel Primer Relay J643 socket
Measure to
21/31
Engine Ground (GND)
Specified value: 12.5 V
If the specified value was not obtained:
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Check the Fuel Primer Relay J643 socket 1/30 to the Battery for an open circuit or short to Ground (GND).
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Check the electrical harness connectors for damage, corrosion, loose or broken terminals.
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If necessary, repair the wiring connection.
If no malfunctions are found in the wiring:
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Using a Multimeter, check the following wiring connection for voltage.
Fuel Primer Relay J643
Measure to
23/87
Engine Ground (GND)
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Crank the engine.
Specified value: 12.5 V
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Switch the ignition off.
If the specified value was not obtained:
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Check the Fuel Primer Relay J643 socket 3/86 to the Power Supply Relay (terminal 15) J329 socket 2/87 for an open circuit or short to Ground
(GND).
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Check the electrical harness connectors for damage, corrosion, loose or broken terminals.
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If necessary, repair the wiring connection.
If no malfunctions are found in the wiring:
Checking Ground (GND)
If the manufacturers test box is being used. Perform the following step.
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Install the test box.
If the manufacturers test box is not being used. Perform the following step.
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Remove the Motronic Engine Control Module (ECM) J220.
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Using a Multimeter, check the following wiring connection for resistance.
Fuel Primer Relay
Motronic Engine Control Module (ECM) J220 electrical
J643 socket
harness connector T121 or test box socket
16/MOT
65
Specified value: 1.5 Ohms.
