New Beetle GLS L4-2.0L (AVH) (2001)
Fuel system is under pressure! Before opening the system, disconnect battery Ground strap and wrap a cloth around the connection. Then release
pressure by carefully loosening the connection.
Test sequence
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Remove inner plenum chamber cover, left:
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Connect test box V.A.G 1598/31 to control module wiring harness. Engine control module is not connected by this action.
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Remove intake manifold upper part.
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Disconnect connectors off injectors.
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Remove fuel rail securing bolts.
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Pull off vacuum hose from fuel pressure regulator.
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Pull hose for air shrouded injectors off air pipe (item 4).
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Lift fuel rail with injectors off intake manifold and support it.
NOTE: Always use new oil seals when installing.
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Bridge connector terminals 1 and 65 using auxiliary cables from V.A.G 1594 and observe display.
NOTE: This step serves only to run the fuel pump when the engine is not running.
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Switch ignition on.
Checking for leaks
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Check injector for leaks (visual check). Only 1 to 2 drops per minute must emit from each valve when fuel pump is running.
If the fuel loss is greater:
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Switch ignition off.
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Replace malfunctioning injector.
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Erase DTC memory to put learned values in a neutral setting. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing
Diagnostic Trouble Codes/Reading Diagnostic Trouble Codes
Checking injected quantity
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V.A.G 1598/31 test box still connected and test box sockets 1 and 65 bridged with adapter cables from VAG 1594 adapter test kit.
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Insert injector to be checked in a measuring glass of tester for injected quantity V.A.G 1602.