2002 Volkswagen EuroVan BaseFACTORY OEM SERVICE PROCEDURE

2.8L VR6 (Engine Code AES)

  1. Ensure battery voltage is at least 11.5 volts. Ensure fuel pump fuse No. 18 is okay. See Figure . Turn ignition off. Remove fuel filler cap.
  2. Relieve fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE (2.8L VR6, ENGINE CODE AES)  .
  3. Connect Pressure Gauge (VAG 1318), or equivalent, at fuel supply line/hose in engine compartment. Ensure shut-off lever is open (position A), and fuel hose is in a measuring container. See Fig 1 .
    Fig 1: Checking Fuel Pump Volume (Engine Code AES)
    G00283880Courtesy of VOLKSWAGEN UNITED STATES, INC.
  4. Remove fuel pump relay from relay panel. Connect Remote Control Switch (VAG 1348) between battery positive source and fuel pump terminal. See Fig 2 .
    Fig 2: Connecting Remote Control Switch (VAG 1348) To Fuel Pump Terminal
    G00283879Courtesy of VOLKSWAGEN UNITED STATES, INC.
  5. Activate fuel pump with remoter control switch and slowly close lever (A) until pressure is at 44 psi (3 bar). See Fig 1 . Once this pressure is reached, do NOT move lever any further. Empty measuring container.
  6. Connect DVOM to battery terminals. Activate fuel pump for 30 seconds while collecting fuel in measuring container and measure battery voltage. Record fuel volume and battery voltage.
  7. Compare quantity of fuel with specification. See Fig 3 .
    NOTE: Voltage shown in graph in Fig 3 is at fuel pump. Battery volage is about 2 volts more than that measured directly at fuel pump.
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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