Volkswagen New Beetle. Manual - part 1582

 

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Volkswagen New Beetle. Manual - part 1582

 

 

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Disconnect harness connector from all fuel injectors.  

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Remove fuel rail assembly.  

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Disconnect vacuum hose from fuel pressure regulator.  

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Lift fuel rail with injectors from intake manifold and support  

Checking for leaks 

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Initiate Output Diagnostic Test Mode and activate cyl. 1 fuel injector -N30. See COMPONENTS AND 
FUNCTIONS, ADAPTING
  

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Fuel pump must run.  

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Visually check fuel injector for leaks.  

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Only 1 to 2 drops per minute allowed from each injector when fuel pump is running.  

If fuel loss is greater than specified: 

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Switch OFF ignition and replace leaking fuel injector.  

Fuel injection quantity, checking 

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Insert injector to be checked in a measuring glass for VAG 1602 Fuel analyzer.  

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Connect one terminal of injector to be tested to engine Ground using jumper wires from VW 1594 
Adaptor kit. 

NOTE:

This check allows the fuel pump to operate without running the engine. The 
Closed Throttle Position switch must remain closed for this check, otherwise 
the selected injector will inject 5 times.

NOTE:

When installing, note the following: 

z

Replace O-rings on all injectors after first moistening the new O-ring with 
clean engine oil.  

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Vertically insert injectors into the correct position in the fuel rail and 
secure with retaining clips.  

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Fit fuel rail with secured injectors onto intake manifold and press in 
evenly.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Multiport Fuel Injection (MFI) - New Beetle, 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)

  

Fig. 30: Connecting Injector Terminal And Jumper Wire To VAG 1348/3A Remote Control Using 
VAG 1348/3-2 Adapter Cable
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Connect other injector terminal and jumper wire to VAG 1348/3A remote control using VAG 1348/3-2 
adapter cable  

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Connect alligator clip to Battery positive (+).  

z

Initiate Output Diagnostic Test Mode and activate cyl. 1 fuel injector -N30-. See COMPONENTS AND 
FUNCTIONS, ADAPTING
 

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Fuel pump must run  

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Operate remote control VAG 1348/3A for 30 seconds.  

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Repeat check for other injectors on this cylinder bank using separate measuring containers. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Multiport Fuel Injection (MFI) - New Beetle, 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)

  

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After all injectors have been activated, place measuring containers on a horizontal surface and compare 
injected quantities. 

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Specification: 85 to 105 ml per injector  

If the measured quantity of one or more injectors are above or below the specification: 

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Replace faulty fuel injector(s). See ENGINE CODES AVH, AZG item -10-  

Install fuel injectors in reverse order of removal procedure. When installing, note the following: 

z

Replace O-rings on all injectors after first moistening the new O-ring with clean engine oil.  

z

Vertically insert injectors into the correct position in the fuel rail and secure with retaining clips.  

z

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 

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V.A.G 1348/3 Remote control  

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V.A.G 1348/3-2 Adapter  

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V.A.G 1602 Calibration tester  

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V.A.G 1594 A Adapter set  

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Test box V.A.G 1598/31 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Multiport Fuel Injection (MFI) - New Beetle, 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)

  

Fig. 31: Identifying Special Tools, Equipment And Measuring Instruments (Engine Codes AVH, 
AZG, BDC, BEV And BGD)
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Requirements 

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Fuel pressure must be OK, checking. See FUEL PRESSURE REGULATOR AND HOLDING 
PRESSURE, CHECKING
 .  

Work sequence 

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Remove inner plenum chamber cover, left: 

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.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Multiport Fuel Injection (MFI) - New Beetle, 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)

  

 

 

 

 

 

 

 

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