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Home >> Volkswagen >> 2005 >> New Beetle Convertible (1Y1) L4-2.0L (BEV) >> Repair and Diagnosis >> Powertrain Management >> Computers and Control Systems >> Testing and Inspection >> Component Tests and General Diagnostics >> Fuel Injectors, Checking

Fuel Injectors, Checking



Fuel Injectors, Checking

Recommended special tools and equipment
- VA.G 1526 multimeter or V.A.G 1715 multimeter
- V.A.G 1527 voltage test lamp
- V.A.G 1594 connector test kit
- Wiring diagram

Requirements







- The respective fuses of fuel injectors (-N30- to -N33-) must be OK.
- Fuel Pump (FP) Relay -J17- must be OK, check
- Battery voltage must be at least 11.5 volts.
- All electrical consumers such as, lights and rear window defroster must be switched off.
- Parking brake must be engaged or else daylight driving lights will be switched on.
- For vehicles with automatic transmission, selector lever must be in position -P- or -N-
- If vehicle is equipped with an A/C system, it must be switched off.
- Ground (GND) connections between engine and chassis must be OK.
- Engine speed (RPM) sensor must be OK, checking. Testing and Inspection
- Ignition switched off.

Work sequence
Observe safety precautions.
Observe rules for cleanliness.
- Remove upper part of intake manifold.

Intake manifold, upper part, disassembling and assembling.

NOTE: Seal the intake channels in lower section of intake manifold using a clean rag.

- Disconnect fuel injector connectors.

Resistance values of fuel injectors, checking







- Test resistance of fuel injectors between terminals.

Specified value: 14.0 to 20.0 Ohms

NOTE: Resistance value is valid at approx. 20 degrees C. At higher temperatures, resistance value increases.

If specified value is not obtained:
- Replace faulty fuel injector.

Note the following when installing the fuel injectors:
- Replace O-rings on all fuel injectors and wet them slightly with clean engine oil.
- Insert fuel injectors into fuel rail perpendicular and in the right position, and secure them with retaining clips.
- Position fuel distributor on lower section of intake manifold using secured fuel injectors and apply uniform pressure to press it in.
- The connectors must audibly engage on injectors when attached.

Vehicles with engine code BEV, BCD
- Bleed fuel system.

Continued for all vehicles
- Erase DTC memory of Engine Control Module (ECM). Diagnostic mode 4: Reset/erase diagnostic data. Diagnostic Mode 4: Reset/Erase Diagnostic Data
- Generate readiness code. Monitors, Trips, Drive Cycles and Readiness Codes

Checking voltage supply

Vehicles with engine code AEG







- Connect diode test lamp to connector of fuel injector to be tested terminal 1 and Ground (GND).

Vehicles with engine code AVH, AZG, BDC, BEV, BGD







- Connect diode test lamp to connector of fuel injector to be tested terminal 1 and Ground (GND).

Continued for all vehicles
- Operate starter and test voltage supply for fuel injector.
LED must light up.
- Switch ignition off.
If LED does not light up:
- Check wire between 2-pin connector terminal 1 and Fuel Pump (FP) Relay -J17- for open circuit according to wiring diagram.

Wire resistance: max. 1.5 Ohms

Activation and voltage supply, checking

Vehicles with engine code AEG







- Connect diode test lamp to connector terminals of fuel injector to be checked.

Vehicles with engine code AVH, AZG, BDC, BEV, BGD







- Connect diode test lamp to connector terminals of the fuel injector to be checked.

Continued for all vehicle
- Operate starter and test activation of fuel injector.
LED should flicker.
- Switch ignition off.
If LED does not flicker:
- Connect test box to control module wiring harness. connect test box for wiring test. Test Box, Connecting For Wiring Test

Vehicles with engine code AEG







- Check wires between test box and 2-pin connector for open circuit according to wiring diagram.

Wire resistance: max. 1.5 Ohms







- Check wires for short circuit to B+ and to Ground (GND).

Specified value: Infinite Ohms

Vehicles with engine code AVH, AZG, BDC, BEV, BGD







- Check wires between test box and 2-pin connector for open circuit according to wiring diagram.

Wire resistance: max. 1.5 Ohms







- Check wires for short circuit to B+ and to Ground (GND).

Specified value: Infinite Ohms

Continued for all vehicles
If there is no malfunction in wire connection:
- Replace Motronic Engine Control Module (ECM) -J220-.







Injection quantity and proper seal of fuel injectors, checking

Recommended special tools and equipment
- V.A.G 1348/3A remote control with V.A.G 1348/3-2 adapter cable
- V.A.G 1602 tester for quantity of injected fuel

Without illustration:
- V.A.G 1594A connector test kit

Requirement
- Fuel pressure must be OK, check. fuel pressure regulator and retaining pressure, checking. Fuel Pressure Regulator and Residual Pressure, Checking

Work sequence

WARNING: Fuel system is under pressure. before opening system, place rags around the connection point. Then release pressure by carefully loosening connection.

- Remove upper part of intake manifold.

Intake manifold, upper part, disassembling and assembling.

NOTE: Seal the intake channels in lower section of intake manifold using a clean rag.

- Disconnect fuel injector connectors.
- Remove and support fuel rail with fuel injectors.

Intake manifold, lower part, disassembling and assembling.
- Connect test box to control module wiring harness. connect test box for wiring test. Test Box, Connecting For Wiring Test

Vehicles with engine code AEG
- Bridge sockets 2 + 4 of test box with respective adapter cables.

Fuel Pump (FP) must run.

Vehicles with engine code AVH, AZG, BDC, BEV, BGD
- Bridge sockets 2 + 65 of test box with respective adapter cables.
Fuel Pump (FP) must run.

Continued for all vehicles
- Switch ignition on.

Checking Proper Seal
- Check fuel injectors for proper seal (visual inspection). With Fuel Pump (FP) running, only 1 to 2 drops per minute should escape from each valve.
- Disconnect connection between test box sockets.
- Switch ignition off.

If fuel loss is greater:
- Replace faulty fuel injector.

Note the following when installing fuel injectors:
- Replace O-rings on all fuel injectors and wet them slightly with clean engine oil.
- Insert fuel injectors into fuel rail perpendicular and in the right position, and secure them with retaining clips.
- Position fuel distributor on lower section of intake manifold using secured fuel injectors and apply uniform pressure to press it in.
- The connectors must audibly engage on injectors when attached.

Vehicles with engine code BEV, BGD
- Bleed fuel system.

Continued for all vehicles
- Erase DTC memory of Engine Control Module (ECM). Diagnostic mode 4: Reset/erase diagnostic data. Diagnostic Mode 4: Reset/Erase Diagnostic Data
- Generate readiness code. Monitors, Trips, Drive Cycles and Readiness Codes

Checking injection quantity
- Insert a fuel injector to be tested into a measuring tube of V.A.G 1602 tester for fuel injection quantity.







- Using respective adapter cables, connect one terminal of fuel injector to be checked to engine Ground (GND).
- Use adapter cable to connect second terminal of fuel injector to V.A.G 1348/3 remote control with V.A.G 1348/3-2 adapter cable.
- Connect alligator clip to B+.
- Switch ignition on.

Vehicles with engine code AEG
- Bridge sockets 2 + 4 of test box with the respective adapter cables.
Fuel Pump (FP) must run.

Vehicles with engine code AVH, AZG, BDC, BEV, BGD
- Bridge sockets 2 + 65 of test box with the respective adapter cables.
Fuel Pump (FP) must run.

Continued for all vehicles
- Operate remote control for 30 seconds.
- Repeat test on other fuel injectors. Use new graduated measuring glasses for this.

NOTE: Check spray pattern when checking injection quantity. Spray pattern must be the same for all injectors

- After all fuel injectors have been activated, place graduated measuring glasses on a level surface and compare quantity of injected fuel.

Specified value: 85 to 105 ml per injector

- Disconnect connection between test box sockets.
- Switch ignition off.

If the measured value of one or more fuel injectors is below or above the indicated specified value:
- Replace faulty fuel injector.

Note the following when installing fuel injectors:
- Replace O-rings on all fuel injectors and wet them slightly with clean engine oil.
- Insert fuel injectors into fuel rail perpendicular and in the right position, and secure them with retaining clips.
- Position fuel distributor on lower section of intake manifold using secured fuel injectors and apply uniform pressure to press it in.
- The connectors must audibly engage on injectors when attached.

Vehicles with engine code BEV, BGD
- Bleed fuel system.

Continued for all vehicles
- Erase DTC memory of Engine Control Module (ECM). Diagnostic mode 4: Reset/erase diagnostic data. Diagnostic Mode 4: Reset/Erase Diagnostic Data
- Generate readiness code. Monitors, Trips, Drive Cycles and Readiness Codes
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