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Home >> Volkswagen >> 2001 >> GTI (1J1) L4-1.8L Turbo (AWW) >> Repair and Diagnosis >> Powertrain Management >> Fuel Delivery and Air Induction >> Fuel Injector >> Testing and Inspection >> Check Injectors For Leaks and Quantity Injected

Check Injectors For Leaks and Quantity Injected



Check Injectors For Leaks and Quantity Injected

Special tools and equipment







- VAG1348/3 Remote control
- VAG1348/3-2 Adapter
- VAG1602 Calibration tester

Test conditions
- The fuel pressure must be in order; check Testing and Inspection


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.


Test sequence
- Pull connectors off injectors.
- Then remove fuel rail complete.
- Pull off vacuum hose from fuel pressure regulator.
- Lift fuel rail with injectors off intake manifold and support it.

Checking for leaks
- Initiate Output Diagnostic Test Mode; the fuel pump must run. Refer to "Scan Tool Testing/Activating Actuators(Output Diagnostic Test Mode) Testing and Inspection


NOTE:
- This step serves only to run the fuel pump when the engine is stopped.
- During the Output Diagnostic Test Mode, the injectors are activated. Before initiate the Output Diagnostic Test Mode, you must disconnect the injector connectors.


- Check 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:
- Switch ignition off.
- Replace faulty injector.

Pay attention to the following when installing the injectors:
- Replace O-rings on all injectors and lightly moisten with clean engine oil.
- Insert injectors vertically and in the correct position into the fuel rail and secure with retaining clips.
- Set fuel distributor with secured injectors on cylinder head and press in evenly.
- The connectors must audibly engage in the injectors when pushed on.

- Check DTC Memory, if necessary, repair any malfunctions and then Erase DTC Memory,Checking and Erasing DTC Memory. Refer to "Displaying and Reading Trouble Codes/With Manufacture Scan Tool/Check DTC Memory (Function 02)" Testing and Inspection
- Read readiness code. If DTC memory has been erased or engine control module was disconnected from permanent positive, readiness code must be generated again:Refer to "Monitors, Trips and/or Drive Cycle/ Reading Readiness Code" Testing and Inspection
Engine code AWW, Refer to "Monitors, Trips and/or Drive Cycle/Generating Readiness Code" Testing and Inspection
Engine code AWP, Refer to "Monitors, Trips and/or Drive Cycle/Generating Readiness Code" Testing and Inspection

Checking injected quantity







- Connect VAG1598/31 test box to control module wiring harness. The engine control module remains disconnected.
- Switch ignition on.
- Bridge sockets 2+65 of test box with adapter cables from VAG1594. Fuel pump must start.


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


- Insert injector to be checked in a measuring glass of tester for injected quantity VAG1602.







- Connect one contact of the injector to be tested to engine Ground (GND) using auxiliary cables from VAG1594.
- Connect the second injector contact with auxiliary cable to VAG1348/3 remote control using VAG1348/3-2 adapter cable.
- Connect alligator clip to battery (+).
- Operate VAG 1348/3 remote control for 30 seconds.
- Repeat check on the other injectors. To do this use new measuring beakers.
- After all injectors have been activated, place the measuring glasses on a horizontal surface and compare the injected quantity.
Specification: 133 to 157 ml per injector


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


- Replace faulty injector.

Perform installation of injectors in reverse order. When doing this note the following:
- Replace O-rings on all injectors and lightly moisten with clean engine oil.
- Insert injectors vertically and in the correct position into the fuel rail and secure with retaining clips.
- Fit fuel rail with secured injectors onto intake manifold and press in evenly.

- Check DTC Memory, if necessary, repair any malfunctions and then Erase DTC Memory,Checking and Erasing DTC Memory. Refer to "Displaying and Reading Trouble Codes/With Manufacture Scan Tool/Check DTC Memory (Function 02)" Testing and Inspection
- Read readiness code. If DTC memory has been erased or engine control module was disconnected from permanent positive, readiness code must be generated again: Refer to "Monitors, Trips and/or Drive Cycle/ Reading Readiness Code" Testing and Inspection
Engine code AWW, Refer to "Monitors, Trips and/or Drive Cycle/Generating Readiness Code" Testing and Inspection
Engine code AWP, Refer to "Monitors, Trips and/or Drive Cycle/Generating Readiness Code" Testing and Inspection
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