Fuel Injection Quantity, Checking

Fuel injection quantity, checking
^ Insert injector to be checked in a measuring glass for VAG1602 Fuel analyzer.





^ Connect one terminal of injector to be tested to engine Ground using jumper wires from VW1594 Adaptor kit.
^ Connect other injector terminal and jumper wire to VAG1348/3A remote control using VAG1348/3-2 adapter cable
^ Connect alligator clip to Battery positive (+).
^ Initiate Output Diagnostic Test Mode and activate cyl. 1 fuel injector -N30-
^ Fuel pump must run
^ Operate remote control VAG1348/3A for 30 seconds.
^ Repeat check for other injectors on this cylinder bank using separate measuring containers.
^ After all injectors have been activated, place measuring containers on a horizontal surface and compare injected quantities.
^ Specification: 85 to 105 ml per injector

If the measured quantity of one or more injectors are above or below the specification:
^ Replace faulty fuel injector(s)

Install fuel injectors in reverse order of removal procedure. When installing, note the following:
^ Replace O-rings on all injectors after first moistening the new O-ring with clean engine oil.
^ Vertically insert injectors into the correct position in the fuel rail and secure with retaining clips.
^ Fit fuel rail with secured injectors onto intake manifold and press in evenly.

Engine codes AVH, AZG, BDC, BEV, BGD
Special tools, equipment, testers, measuring instruments and auxiliary items required





^ VAG1348/3 Remote control
^ VAG1348/3-2 Adapter
^ VAG1602 Calibration tester
^ VAG1594A Adapter set
^ Test box VAG1598/31

Requirements
^ Fuel pressure must be OK.

WARNING: Fuel system is under pressure! Before opening the system remove fuse 28 and place a cloth around the connection. Then release pressure by carefully loosening the connection.

Work sequence
^ Remove inner plenum chamber cover, left:





^ Connect test box VAG1598/31 to control module wiring harness. Engine control module remains disconnected.
^ Remove intake manifold upper part.
^ Disconnect connectors from all injectors.
^ Remove securing bolts on fuel rail.

Engine codes AVH, AZG, BDC
^ Pull vacuum hose off fuel pressure regulator.
^ Pull hose off air pipe for air shrouded injectors.

Continuation for all models
^ Lift fuel rail along with injectors off intake manifold and support.
^ Bridge test box sockets 1 and 65 using adapter cable from adapter set VAG1594.

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 replace leaky injector.

Note: Always replace O-rings on all injectors after first moistening the new O-ring with clean engine oil.

^ Erase fault memory to return learned values to a neutral (default) position.

Checking quantity injected
Requirements
^ Test box VAG1598/31 still connected and test box sockets 1 and 65 are still bridged using adapter cables from adapter set VAG1594.
^ Insert injector to be checked in a measuring glass of calibration tester VAG1602.





^ Connect one contact of injector to be tested to engine Ground using adapter cables from VAG1594.
^ Using adapter cables connect second injector contact to remote control VAG1348/3 with adapter cable VAG1348/3-2.
^ Connect alligator clip to Battery positive (+).
^ Switch on ignition, fuel pump must run.
^ Operate remote control VAG1348/3 for 30 seconds.
^ Repeat check on other injectors. Use another (clean and dry) measuring beaker for this.
^ After all injectors have been activated, place measuring glasses on a horizontal surface and compare quantity injected.
^ Specification: 85...1.05 ml per injector

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

^ Replace faulty injector.
^ Erase fault memory to return learned values to a neutral (default) position.

Perform installation of injectors in reverse order. Note the following:
^ Replace O-rings on all injectors and moisten them 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.