New Beetle GLS L4-2.0L (AZG) (2002)
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Vehicles with engine code BDC, item 7.
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Lift fuel distributor with fuel injectors off lower part of intake manifold and support it.
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Connect test box to control module wiring harness, connect test box for wiring test. See: Computers and Control Systems/Testing and
Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring
Test
Checking Proper Seal
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Switch ignition on.
Vehicles with engine code AEG
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Bridge sockets 2 + 4 of test box with the respective adapter cables. Fuel Pump (FP) must run.
Vehicles with engine code AVH, AZG, BDC
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Bridge sockets 2 + 65 of test box with the respective adapter cables. Fuel Pump (FP) must run.
Continuation for all vehicles
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Check proper seal of fuel injectors (visual inspection). With Fuel Pump (FP) running, only 1 to 2 drops per minute should escape from each valve.
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Disconnect connection between test box sockets.
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Switch ignition off.
If fuel loss is greater:
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Replace faulty fuel injector:
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Vehicles with engine code AEG, AVH, AZG, item 7,
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Vehicles with engine code BDC, item 9.
Note the following when installing the fuel injectors:
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Replace O-rings on all fuel injectors and wet them slightly with clean motor oil.
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Insert fuel injectors into fuel distributor perpendicular and in the right position, and secure them with retaining clips.
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Position fuel distributor with secured fuel injectors on lower part of intake manifold and apply uniform pressure to press it in.
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The connectors must audibly engage on valves when attached.
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Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data.
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Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes
Checking Injection Quantity
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Insert a fuel injector to be tested into a measuring tube of VAG1602 tester for fuel injection quantity.
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Using respective adapter cables, connect one terminal of fuel injector to be checked to engine Ground (GND).
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Use adapter cable to connect second terminal of fuel injector to VAG 1348/3 remote control with VAG 1348/3-2 adapter cable.
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Connect alligator clip to B+.
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Switch ignition on.
Vehicles with engine code AEG
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Bridge sockets 2 + 4 of test box with the respective adapter cables. Fuel Pump (FP) must run.