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Fuel Pump Electrical, Testing

Special tools and workshop equipment required 

Test conditions 

Test procedure 

-- Perform a preliminary check to verify the customers complaint. Refer to PRELIMINARY CHECK 

Start diagnosis 

-- Remove rear seat. Refer to the Repair information.

-- Remove the Fuel Pump Control Module -J538- - 2- from the retaining clips on tank mount -1-.

Fig 1: Identifying Fuel Pump Control Module Bracket -1-, Fuel Pump Control Module -2- And Connector -3-
GWWN20-10448Courtesy of AUDI OF AMERICA, LLC

-- Disconnect the electrical harness connector -3- from the Fuel Pump Control Module -J538-.

Fig 2: 5-Pin Electrical Harness Connector & Terminals
GWWA23-0058Courtesy of AUDI OF AMERICA, LLC

-- Connect the multimeter ground lead to terminal -4- of the Fuel Pump Control Module -J538- harness connector.

-- Connect the multimeter positive lead to terminal -3- of the Fuel Pump Control Module -J538- harness connector.

-- Turn the Ignition switch to the ON position.

-- The meter should read within 1 volt of battery voltage.

-- Turn the ignition switch OFF

-- If voltage is below specification, locate wiring fault in ground or power circuit. Refer to wiring diagram for location.

-- If voltage is OK, connect multimeter positive lead to terminal -5- of the Fuel Pump Control Module -J538- harness connector. The ground lead remains on terminal -4-

-- Turn the ignition switch ON and note voltage displayed on multimeter. Voltage should be near 0.330 - 0.350 V.

-- Turn the ignition switch OFF

-- If voltage is below specification, locate wiring fault in the ECM control circuit T94 terminal 30, to fuel pump module terminal 5. Refer to wiring diagram for location.

-- If voltage is OK, reconnect the wiring harness to the Fuel Pump Control Module -J538-.

Test procedure for Fuel Pump 

-- Remove the floor sealing cover to access the Fuel Delivery Unit (fuel pump).

Fig 3: Identifying Connectors -1- And -2-
GWWN20-10438Courtesy of AUDI OF AMERICA, LLC

-- Disconnect the harness connector -1- from the Fuel Delivery Unit (fuel pump).

-- Connect the multimeter positive lead to terminal -1- of the Fuel Delivery Unit (fuel pump) harness connector.

-- Connect the multimeter ground lead to terminal -5- of the Fuel Delivery Unit (fuel pump) harness connector.

Fig 4: 5-Pin Electrical Harness Connector & Terminals
GWWA23-0058Courtesy of AUDI OF AMERICA, LLC

-- Crank the engine and note voltage displayed on multimeter during crank. Voltage should be within 3.0 volts of Battery voltage.

If voltage is below specification, check the wiring between the Fuel Pump Control Module -J538- and the fuel delivery unit (fuel pump) for an open or high resistance and repair if necessary. If the harness is OK, replace the Fuel Pump Control Module -J538-.

If voltage is within specification, replace the Fuel Delivery Unit (Fuel Pump). Refer to the Repair information.

Final procedures 

After the repair work, the following work steps must be performed in the following sequence:

  1. Check the DTC memory. Refer to DIAGNOSTIC MODE 03 - READ DTC MEMORY .
  2. If necessary, erase the DTC memory. Refer to DIAGNOSTIC MODE 04 - ERASE DTC MEMORY .
  3. If the DTC memory was erased, generate readiness code. Refer to READINESS CODE .
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