Volkswagen New Beetle. Manual - part 1681

Test sequence 

z

Disconnect connectors from fuel injectors. 

Fig. 84: Disconnecting Connectors From Fuel Injectors 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Remove fuel rail complete.  

z

Disconnect vacuum hose from fuel pressure regulator.  

z

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

WARNING:

Fuel system is under pressure! Before opening the system place a cloth 
around the connection. Then release pressure by carefully loosening the 
connection.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

  

Checking for leaks 

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Initiate output Diagnostic Test Mode (DTM), see OUTPUT DIAGNOSTIC TEST MODE (DTM) 
(FUNCTION 03), INITIATING (fuel pump must run). 

z

Check fuel 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 off ignition.  

z

Replace malfunctioning fuel injector, see item 10 .  

Pay attention to the following when installing the fuel injector: 

z

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

z

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

z

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

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The connectors must audibly engage in the fuel injectors when pushed on.  

z

Check DTC Memory, if necessary, repair any malfunctions and then Erase DTC Memory, see DTC 
MEMORY OF MOTRONIC ENGINE CONTROL MODULE (ECM) -J220-, CHECKING AND 
ERASING .  

z

Read readiness code, see READINESS CODE, DISPLAYING . If DTC memory has been erased or 
Motronic Engine Control Module (ECM) -J220- was disconnected from battery positive, readiness code 
must be generated again, see READINESS CODE, GENERATING .  

Checking injected quantity 

z

Insert fuel injector to be checked in a measuring glass of VAG 1602 tester for injected quantity.  

z

Connect one terminal of fuel injector to be tested to engine Ground (GND) using auxiliary cables from 
VAG 1594.  

z

Connect second fuel injector terminal with auxiliary cable to VAG 1348/3 remote control using VAG 
1348/3 -2 adapter cable. 

NOTE:

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

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

  

Fig. 85: Connecting One Terminal Of Fuel Injector To Engine Ground (Gnd) Using Auxiliary 
Cables From VAG 1594 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Connect alligator clip to battery (+).  

z

Initiate output DTM, see OUTPUT DIAGNOSTIC TEST MODE (DTM) (FUNCTION 03), 
INITIATING (fuel pump must run).  

z

Operate VAG 1348/3 remote control for 30 seconds.  

z

Repeat check on other fuel injectors. Use new measuring glasses.  

z

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

NOTE:

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

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

  

Specification: 133 to 157 ml per injector 

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

z

Switch off ignition.  

z

Replace malfunctioning fuel injector, see item 10 .  

Pay attention to the following when installing the fuel injector: 

z

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

z

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

z

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

z

Check DTC Memory, if necessary, repair any malfunctions and then Erase DTC Memory, see DTC 
MEMORY OF MOTRONIC ENGINE CONTROL MODULE (ECM) -J220-, CHECKING AND 
ERASING .  

z

Read readiness code, see READINESS CODE, DISPLAYING . If DTC memory has been erased or 
Motronic Engine Control Module (ECM) -J220- was disconnected from battery positive, readiness code 
must be generated again, see READINESS CODE, GENERATING .  

Fuel pressure regulator and holding pressure, checking 

The fuel pressure regulator controls the fuel pressure dependent upon intake manifold pressure. 

Special tools, test equipment and auxiliary items 

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VAG 1318 Pressure gauge  

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1318/9 Adapter  

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1318/17 Adapter 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle