Volkswagen Golf / Golf GTI / Golf Variant. Manual - part 205

Step

Procedure

Result / Action to Take

5

• Final Procedure
• Perform a road test to verify repair.
– Does the original DTC return?

– YES:

♦ CHECK: Engine Control Module - J623- har‐

ness connector for any damaged, pushed-out

pins.

♦ REPAIR: As necessary.
♦ Clear the DTC’s. Refer to

⇒ “3.3.4 Diagnostic Mode 04 - Erase DTC

Memory”, page 26

 .

♦ Repair is complete. Generate Readiness

Code. Refer to

⇒ “3.2 Readiness Codes”, page 19

 .

♦ Return vehicle to Customer.
♦ If all electrical connections are OK:
♦ REPLACE: Engine Control Module - J623- .

Refer to appropriate repair manual.

♦ Repair is complete. Generate Readiness

Code. Refer to

⇒ “3.2 Readiness Codes”, page 19

 .

♦ Return vehicle to Customer.
– NO:

♦ Perform the diagnostic procedure for any

DTC’s.

♦ If no DTC’s return the repair is complete.
♦ Return vehicle to customer.

3.6.18

Fuel Pump Control Module - J538- / Fuel

Delivery Unit - GX1- , Checking

General Description
The Engine Control Module - J623- tells the Fuel Pump Control

Module - J538- the demand needed for fuel volume and pressure

and activates the Fuel Delivery Unit - GX1- . The Fuel Delivery

Unit - GX1- transfers fuel to the rest of the fuel system, where it

is monitored by the Engine Control Module - J623- through sen‐

sors, and controlled through regulators and/or metering valves.
Special tools and workshop equipment required
♦ Multimeter.
♦ Wiring Diagram.
♦ Scan Tool.
Test requirements
• Fuses OK.
• Battery voltage OK.
• Switch OFF all electrical and electronic accessories.
• Vehicles with Auto. Transmission, ensure Selector Lever po‐

sition is in “P”.

• Vehicles with Man. Transmission, ensure Shifter Lever posi‐

tion is in “N” with Parking Brake applied.

• Coolant Temperature: ≥ 80° C.

GTI 2014 ➤

Generic Scan Tool - Edition 04.2015

3. Diagnosis and Testing    

493

• Observe all safety precautions:

⇒ “1.1 Safety Precautions”, page 2

 .

• View clean working conditions:

⇒ “1.2 Clean Working Conditions”, page 3

 .

• For Hybrid vehicles refer to:

⇒ “1.3 High Voltage System General Warnings”, page 4

 .

Test Procedure

Note

When the door is opened or the Ignition is turned to the ON po‐

sition the fuel pump is activated for 2 seconds to build up the

pressure in the fuel system.

Step

Procedure

Result / Action to Take

1

• PERFORM: Preliminary Check to verify the

customers complaint. Refer to

⇒ “3.1 Preliminary Check ”, page 18

 .

– Was Complaint verified?

– YES:

♦ GO TO: Step 2 

⇒ page 494

 .

♦ NO:
♦ GATHER more Information from customer

about the complaint.

2

• IGNITION: ON.
• LISTEN: Fuel Delivery Unit - GX1- Should be

heard running for 2 s.

• SPECIFIED VALUE: Transfer Fuel Pump ON

for 2 s.

• IGNITION: OFF.
– Was Value obtained?

– YES:

♦ Condition may be intermittent.
♦ PERFORM: Visual Inspection of wiring and

component.

♦ CHECK: Wiring for open, high resistance,

short or harness connector for damage, corro‐

sion, loose or broken terminals.

♦ REPAIR: Faulty wiring or connector.
♦ GO TO: Step 7 

⇒ page 496

 .

♦ NO:
♦ GO TO: Step 3 

⇒ page 494

 .

3

• IGNITION: OFF.
• DISCONNECT: Fuel Pump Control Module. -

J538-

• IGNITION: ON.
• CHECK: Fuel Pump Control Module - J538-

harness connector terminals 3 to 4 for voltage.

• CHECK: Fuel Pump Control Module - J538-

harness connector terminal 4 to battery voltage

for voltage.

• CHECK: Fuel Pump Control Module - J538-

harness connector terminal 3 to ground for

voltage.

• SPECIFIED VALUE: Battery voltage.
• IGNITION: OFF.
– Were Values obtained?

– YES:

♦ GO TO: Step 4 

⇒ page 495

 .

♦ NO:
♦ PERFORM: Visual Inspection of wiring and

component.

♦ CHECK: Wiring for open, high resistance,

short or harness connector for damage, corro‐

sion, loose or broken terminals.

♦ REPAIR: Faulty wiring or connector.
♦ GO TO: Step 7 

⇒ page 496

 .

GTI 2014 ➤

Generic Scan Tool - Edition 04.2015

494

     Rep. Gr. ST - Generic Scan Tool

Step

Procedure

Result / Action to Take

4

• RECONNECT: Fuel Pump Control Module -

J538- .

• DISCONNECT: Fuel Delivery Unit - GX1- .
• CRANK: Engine.
• CHECK: Fuel Delivery Unit - GX1- harness

connector terminals 1 to 5 for voltage while en‐

gine is cranking.

• IGNITION: OFF.
• SPECIFIED VALUE: 7 – 11 V.
– Was Value obtained?

– YES:

♦ REPLACE: Fuel Delivery Unit - GX1- , Refer to

appropriate repair manual.

♦ GO TO: Step 7 

⇒ page 496

 .

♦ NO:
♦ GO TO: Step 5 

⇒ page 495

 .

5

• DISCONNECT: Fuel Pump Control Module -

J538- .

• CHECK: Fuel Delivery Unit - GX1- harness

connector terminal 1 to Fuel Pump Control

Module - J538- wiring connector 1 for resist‐

ance.

• CHECK: Fuel Delivery Unit - GX1- harness

connector terminal 5 to Fuel Pump Control

Module - J538- wiring connector 2 for resist‐

ance.

• SPECIFIED VALUE: 0.5 Ω ( ± 0.3 Ω ).
– Were values obtained?

– YES:

♦ GO TO: Step 6 

⇒ page 495

 .

♦ NO:
♦ PERFORM: Visual Inspection of wiring and

component.

♦ CHECK: Wiring for open, high resistance,

short or harness connector for damage, corro‐

sion, loose or broken terminals.

♦ REPAIR: Faulty wiring or connector.
♦ GO TO: Step 7 

⇒ page 496

 .

6

• REMOVE: Engine Control Module - J623- .

Refer to appropriate repair manual.

• CHECK: Fuel Pump Control Module - J538-

harness connector terminal 5 to Engine Con‐

trol Module - J623- wiring connector terminal

T91 / 9 for resistance.

• SPECIFIED VALUE: 0.5 Ω ( ± 0.3 Ω ).
– Were values obtained?

– YES:

♦ REPLACE: Fuel Pump Control Module -

J538- . Refer to appropriate repair manual.

♦ GO TO: Step 7 

⇒ page 496

 .

♦ NO:
♦ PERFORM: Visual Inspection of wiring and

component.

♦ CHECK: Wiring for open, high resistance,

short or harness connector for damage, corro‐

sion, loose or broken terminals.

♦ REPAIR: Faulty wiring or connector.
♦ GO TO: Step 7 

⇒ page 496

 .

GTI 2014 ➤

Generic Scan Tool - Edition 04.2015

3. Diagnosis and Testing    

495

Step

Procedure

Result / Action to Take

7

• Final Procedure
• Perform a road test to verify repair.
– Does the original DTC return?

– YES:

♦ CHECK: Engine Control Module - J623- har‐

ness connector for any damaged, pushed-out

pins.

♦ REPAIR: As necessary.
♦ Clear the DTC’s. Refer to

⇒ “3.3.4 Diagnostic Mode 04 - Erase DTC

Memory”, page 26

 .

♦ Repair is complete. Generate Readiness

Code. Refer to

⇒ “3.2 Readiness Codes”, page 19

 .

♦ Return vehicle to Customer.
♦ If all electrical connections are OK:
♦ REPLACE: Engine Control Module - J623- .

Refer to appropriate repair manual.

♦ Repair is complete. Generate Readiness

Code. Refer to

⇒ “3.2 Readiness Codes”, page 19

 .

♦ Return vehicle to Customer.
– NO:

♦ Perform the diagnostic procedure for any

DTC’s.

♦ If no DTC’s return the repair is complete.
♦ Return vehicle to customer.

3.6.19

Fuel Tank Leak Detection Control Mod‐

ule - J909- / Fuel Tank Pressure Sensor

- G400- , Checking

General Description
The system can test the evaporative system integrity by using

natural vacuum after the engine is shut off. The Engine Control

Module - J623- monitors the ability of the system to maintain vac‐

uum through signals sent from the Fuel Tank Pressure Sensor -

G400- / Fuel Tank Leak Detection Control Module - J909- . If the

vacuum remains for a specified period of time, then there are no

evaporative leaks, and a PASS is reported by the Engine Control

Module - J623- . If there is a leak, the system either will not ach‐

ieve a vacuum, or a vacuum cannot be maintained. Usually a fault

can only be detected after a cold start.
Special tools and workshop equipment required
♦ Multimeter.
♦ Wiring Diagram.
♦ Scan Tool.
Test requirements
• Fuses OK.
• Battery voltage OK.
• Switch OFF all electrical and electronic accessories.

GTI 2014 ➤

Generic Scan Tool - Edition 04.2015

496

     Rep. Gr. ST - Generic Scan Tool