Volkswagen Golf / Golf GTI / Golf Variant. Manual - part 760

Perform the following work:
Checking the Fuel Delivery Rate Inside the Engine Compartment,

Quick Test:

Note

The fuel delivery rate is first checked in the engine compartment

with the “Check fuel delivery rate, quick test” Guided Function.

Perform a second measurement on the fuel delivery unit flange if

the minimum delivery rate is not attained.

– Connect the Vehicle Diagnostic Tester .
– Start Guided Functions.
– Check the fuel delivery rate function and select the quick test.
– Follow the instructions displayed on the Vehicle Diagnostic

Tester .

If the Specified Value is not Obtained:
– Open the fuel filler door unit -2-.
– Clean the area around the fuel filler neck.
– Remove the cap -1- for the fuel filler neck.
– Repeat checking the fuel delivery rate, quick test. Refer to

⇒ page 105

 .

If the Specified Value is Obtained:
– Check the fuel tank ventilation. Refer to

⇒ “6.4.1 Fuel Tank, Checking Ventilation, with Fuel Tank Leak

Detection”, page 72

 .

If the Specified value is not Obtained:
– Check the fuel lines for possible restrictions (kinks) or block‐

ages.

– Check the fuel lines for leaks and damage.
If no Error Can Be Found:
Check the fuel delivery rate on the fuel delivery unit as follows:
Fuel Delivery Rate, Checking on Fuel Delivery Unit:

Note

♦

Disconnect the connector couplings. Refer to

⇒ “4.1 Connector Couplings, Disconnecting”, page 62

 .

♦ If driving is still impaired with the fuel tank 

1

/4 full, then perform

a fuel delivery test with the fuel tank only 

1

/4 full or with very

little fuel in the fuel tank.

• Voltage supply OK. Refer to

⇒ “8.1.1 Fuel Pumps, Checking Function and Power Supply”,

page 81

 .

• Fuel pressure is OK. Refer to

⇒ “8.1.3 Fuel Pressure, Checking”, page 87

 .

• The battery voltage must be minimum 11.5 V. Charge the bat‐

tery if necessary. Refer to ⇒  Electrical Equipment; Rep. Gr. 

27 ; Battery; Battery, Charging .

• Fuel Pump Control Module - J538- is OK use the Vehicle Di‐

agnostic Tester ⇒ Vehicle diagnostic tester.

– Pay attention to all safety precautions. Refer to

⇒ “1 Safety Precautions”, page 1

 .

– Follow the guidelines for clean working conditions. Refer to

⇒ “3.1 Parking/Auxiliary Heater and Fuel System Clean Work‐

ing Conditions”, page 4

 .

– Connect the battery charger. Refer to ⇒  Electrical Equipment;

Rep. Gr.  27 ; Battery; Battery, Charging .

Golf Sportsvan:
– Remove the right rear seat. Refer to ⇒  Body Interior; Rep. Gr. 

72 ; Rear Seats; Bench Seat / Single Seat, Removing and In‐

stalling .

– Partially loosen the cover -1- in the carpet at the separating

line -arrow-.

– Do not separate the cover completely from the carpet so that

later it will be installed correctly.

– Only loosen so far that the cover can be folded up.
– Fold up the cover in the direction of the -arrow-.
Golf and Golf Wagon:
– Remove the rear bench seat. Refer to ⇒  Body Interior; Rep.

Gr.  72 ; Rear Seats; Bench Seat / Single Seats, Removing

and Installing .

Continuation for All Vehicles:
– Unclip the sealing flange cover -1- at the tabs -arrows- using

the -3409- .

– Unclip the grommet -1- downward out of the cover -2-.
– Guide the cover -2- on the wiring harness -3- toward the rear.

– Lift the tab -2- in the direction of the -arrow A- by using a finger

to reach between the floor panel and the fuel tank.

– At the same time, pull the Fuel Pump Control Module -1- on

the wiring harness -3- in direction of the -arrow B- carefully out

of the mount.

– Remove the Fuel Pump Control Module - J538- toward the

inside between the fuel tank and the floor panel.

– Move the Fuel Pump Control Module - J538- to the side with

the connector connected.

– Pull on the connector -1- without pressing the release to make

sure the connection is secure. If the connector was not con‐

nected correctly, it could cause a malfunction.

– Release and disconnect the connector -1-.
– Check the contacts on the connector and on the fuel delivery

unit for damage.

– Remove the connector -2- (if equipped) from the bracket.

– Connect the -VAS5565- to the fuel delivery unit -1-.
– Connect the -VAG1348/3A- to the -VAS5565- and the battery

positive terminal clamp in the engine compartment.

– Connect the connection -5- (yellow) on the -VAS5565- to the

battery negative terminal using suitable service equip‐

ment-3-.

– To do so, use the -VAG1594D- also.

Note

This step allows the fuel pump to run when the engine is not run‐

ning.

– Remove the fuel lines -1- from the flange. Disconnect the con‐

nector couplings. Refer to

⇒ “4.1 Connector Couplings, Disconnecting”, page 62

 .

WARNING

The fuel line is under pressure.
Fuel poses a risk of injury to the eyes and skin.
Wear protective eyewear and protective clothing to avoid injury

and contact with skin. Place a cleaning cloth around the con‐

nection  point  before  loosening  hose  connections.  Carefully

open the connection point to release the pressure.

– The fuel pump delivery rate is dependent on the battery volt‐

age. Connect the Multimeter to the connectors -1- and -5- of

the -VAS5565- .

– Connect the Multimeter with the -VAG1594D- .