Volkswagen New Beetle. Manual - part 1583

 

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Volkswagen New Beetle. Manual - part 1583

 

 

See PLENUM CHAMBER INNER COVER, REMOVING AND INSTALLING 

z

Connect test box V.A.G 1598/31 to control module wiring harness. Engine control module remains 
disconnected. 

Fig. 32: Connecting Test Box V.A.G 1598/31 To Control Module Wiring Harness 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

z

Remove intake manifold upper part. See INTAKE MANIFOLD UPPER PART, REMOVING AND 
INSTALLING
 .  

z

Disconnect connectors from all injectors.  

z

Remove securing bolts on fuel rail.  

Engine codes AVH, AZG, BDC 

z

Pull vacuum hose off fuel pressure regulator.  

z

Pull hose off air pipe for air shrouded injectors (See Fig. 15 , item -5-).  

Continuation for all models 

z

Lift fuel rail along with injectors off intake manifold and support.  

z

Bridge test box sockets 1 and 65 using adapter cable from adapter set V.A.G 1594. 

z

Switch on ignition.  

Checking for leaks 

z

Check injector for leaks (visual check).  

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

If the fuel loss is greater: 

z

Switch off ignition and replace leaky injector.  

z

Erase fault memory to return learned values to a neutral (default) position. See ENGINE CONTROL 
MODULE FAULT MEMORY, INTERROGATING AND ERASING
 .  

Checking quantity injected 

Requirements 

z

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.  

z

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

z

Connect one contact of injector to be tested to engine Ground using adapter cables from V.A.G 1594. 

NOTE:

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

NOTE:

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

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 33: Using Adapter Cables Connecting Second Injector Contact To Remote Control V.A.G 
1348/3A With Adapter Cable V.A.G 1348/3-2
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Using adapter cables connect second injector contact to remote control V.A.G 1348/3 with adapter cable 
V.A.G 1348/3-2.  

z

Connect alligator clip to Battery positive (+).  

z

Switch on ignition, fuel pump must run. 

 

2003 Volkswagen New Beetle GLS 

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

  

z

Operate remote control V.A.G 1348/3 for 30 seconds.  

z

Repeat check on other injectors. Use another (clean and dry) measuring beaker for this.  

z

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

z

Specification: 85...105 ml per injector  

z

Replace faulty injector.  

z

Erase fault memory to return learned values to a neutral (default) position. See ENGINE CONTROL 
MODULE FAULT MEMORY, INTERROGATING AND ERASING
 .  

Perform installation of injectors in reverse order. Note the following: 

z

Replace O-rings on all injectors and moisten them lightly with clean engine oil.  

z

Insert injectors vertically and in the correct position into the fuel rail and secure with retaining clips.  

z

Set fuel rail with secured injectors on intake manifold and press in evenly.  

FUEL PRESSURE REGULATOR AND HOLDING PRESSURE, CHECKING 

Engine code AEG, AVH, AZG 

z

Engine code BDC. See ENGINE CODE BDC  

z

Engine codes BEV, BGD. See ENGINE CODES BEV, BGD  

The fuel pressure regulator regulates the fuel pressure depending on intake manifold pressure. 

Special tools, test equipment and auxiliary items 

z

V.A.G1318 Pressure gauge  

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1318/10 Adapter  

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1318/11 Adapter  

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1318/16 Adapter  

z

V.A.G 1921 hose clamp pliers 

NOTE:

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

 

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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