Volkswagen Workshop Service and Repair Manuals

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

• ◆ V.A.G 1348/3 Remote control
• ◆ V.A.G 1348/3-2 Adapter
• ◆ V.A.G 1602 Calibration tester
• ◆ V.A.G 1594 A Adapter set
• ◆ V.A.G 1598/31 Test box

Test prerequisites

• ● The fuel pressure must be in order, checking
  .

Test sequence

• ‒ Remove wiper arms and cowl panel:

=> Electrical system; Repair group 92; Windscreen wiper system; Removing and installing windscreen wiper system

• ‒ → Connect test box V.A.G 1598/31 to control unit wiring harness. The engine control unit remains disconnected.
• ‒ Remove intake manifold upper part .
• ‒ Pull connector off all injectors.
• ‒ Remove securing bolts on fuel rail.

• ‒ Pull hose off air pipe for air shrouded injectors ( , item 5).
• ‒ Lift fuel rail along with injectors off intake manifold and support.
• ‒ Bridge test box sockets 1 and 65 using adapter cable from adapter set V.A.G 1594.

Note:

This work sequence allows the fuel pump to run when the engine is not running.

• ‒ Switch on ignition.

Checking for leaks

• ‒ Check injector for leaks (visual check). Only 1 to 2 drops per minute must emit from each injector when fuel pump is running.

If the fuel loss is greater:

• ‒ Switch off ignition and renew leaky injector.
• ‒ Erase the fault memory to return the learnt values to a neutral (default) position => page 24-46 , Interrogating and erasing fault memory

Note:

Always renew seals.

Checking quantity injected

Test prerequisites

• ● Test box V.A.G 1598/31 still connected and test box sockets 1 and 65 are still bridged using adapter cables from adapter set V.A.G 1594.

• ‒ Insert injector to be checked in a measuring glass of calibration tester V.A.G 1602.

• ‒ → Connect one contact of the injector to be tested to engine earth using adapter cables from V.A.G 1594.
• ‒ Using adapter cables connect the second injector contact to remote control V.A.G 1348/3 with adapter cable V.A.G 1348/3-2.
• ‒ Connect crocodile clip to battery (+).
• ‒ Switch on ignition, the fuel pump must run.
• ‒ Operate remote control V.A.G 1348/3 for 30 seconds.
• ‒ Repeat check on the other injectors. Use another (clean and dry) measuring beaker for this.

• ‒ After all injectors have been activated, place the measuring glasses on a horizontal surface and compare the quantity injected.
       Specification: 85...105 ml per injector

If the measured values of one or more injectors are above or below the prescribed specifications:

• ‒ Renew defective injector
• ‒ Erase the fault memory to return the learnt values to a neutral (default) position => page 24-46 , Interrogating and erasing fault memory

Perform installation of injectors in reverse order. When doing this note the following:

• ◆ Renew O-rings on all injectors and moisten then lightly with clean engine oil.
• ◆ Insert injectors vertically and in the correct position into the fuel rail and secure with retaining clips.
• ◆ Set fuel rail with secured injectors on intake manifold and press in evenly.