Engine code AEG Volkswagen Golf Mk4

Engine code AEG

1. Engine codes AVH, AZG, BBW, BEV. Refer to «Engine codes AVH, AZG, BBW»(ref-254999-S35763906542007053000000)

Scheme 259

Special tools and equipment

1. V.A.G 1348/3 Remote control
2. V.A.G 1348/3-2 Adapter
3. V.A.G 1602 Calibration tester

Requirements

1. Fuel pressure must be OK, checking. Refer to «Fuel pressure regulator and holding pressure, checking»(ref-254999-S36118042952007052300000)

Work sequence

1. Remove intake manifold upper part. Refer to «Engine code AEG»(ref-254999-S35336515552007053000000)
2. Disconnect connectors from all injectors.
3. Remove vacuum hose from fuel pressure regulator.
4. Loosen securing bolts for fuel rail.

1. Remove hose from air shrouded injectors.
2. Remove fuel rail complete.

Checking for leaks

1. Initiate final control diagnosis and activate Cylinder 1 Fuel Injector -N30-. Fuel pump must run.

Note. This step serves only to have the fuel pump running when the engine is stopped. The idling speed switch must remain closed for this check, otherwise the selected injector will activate and inject 5 times.

1. Check injectors for leaks (visual check). Only 1 to 2 drops per minute may emit from each valve when fuel pump is running.

If fuel loss is greater

1. Switch ignition off.
2. Replace faulty injector.

Pay attention to the following when installing the injectors

1. Replace O-ring and moistened with clean oil on all injectors.
2. Insert injectors vertically and in the correct position into the fuel rail and secure with retaining clips.
3. Set fuel rail with secured injectors on intake manifold and press in evenly.

Checking quantity injected

Requirements

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

Scheme 260

1. Connect one contact of injector to be tested to engine Ground using adapter cables from V.A.G 1594.
2. Using adapter cables connect second injector contact to remote control V.A.G 1348/3 with adapter cable V.A.G 1348/3-2.
3. Connect alligator clip to battery positive (+).
4. Initiate final control diagnosis and activate Cylinder 1 Fuel Injector -N30-. Fuel pump must run.

1. Operate remote control V.A.G 1348/3 for 30 seconds.
2. Repeat check on other injectors. Use another (clean and dry) measuring beaker for each.
3. After all injectors have been activated, place measuring glasses on a horizontal surface and compare quantity injected.

Specification: 85 to 105 ml per injector

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

1. Replace faulty injector

Perform installation of injectors in reverse order. Note the following

1. Replace O-rings on all injectors and moisten then lightly with clean engine oil.
2. Insert injectors vertically and in the correct position into the fuel rail and secure with retaining clips.
3. Set fuel rail with secured injectors on intake manifold and press in evenly.

Scheme 261

Special tools and equipment

1. V.A.G 1348/3 Remote control
2. V.A.G 1348/3-2 Adapter
3. V.A.G 1602 Calibration tester
4. V.A.G 1594 A Adapter set

1. V.A.G 1598/31 Test box

Requirements

1. Fuel pressure must be OK, checking. Refer to «Fuel pressure regulator and holding pressure, checking»(ref-254999-S36118042952007052300000) .

Work sequence

1. Remove wiper arms and cowl panel

Refer to WINDSHIELD WIPER ASSEMBLY, REMOVING AND INSTALLING

Scheme 262

1. Connect test box V.A.G 1598/31 to control module wiring harness. Engine control module remains disconnected.
2. Remove intake manifold upper part. Refer to «Intake manifold upper part, removing and installing»(ref-254999-S34584153082007052300000) .
3. Disconnect connector from all injectors.

Engines: AVH, AZG

1. Remove vacuum hose from fuel pressure regulator

Continued for all engines

1. Remove securing bolts on fuel rail.
2. Pull hose off air line for air shrouded injectors.
3. Lift fuel rail along with injectors off intake manifold and support.
4. Bridge test box sockets 1 and 65 using adapter cable from adapter set V.A.G 1594.

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

1. Switch ignition on.

Checking for leaks

1. Check injector for leaks (visual check).

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

If fuel loss is greater

1. Switch ignition off and replace leaky injector.
2. Erase DTC memory to return learned values to a neutral (default) position. Refer to «Engine control module Diagnostic Trouble Code (DTC) memory, interrogating and erasing»(ref-254999-S33244134722007052300000) , Interrogating and erasing DTC memory

Note. Always replace O-rings and moisten them with engine clean oil.

Checking quantity injected

Requirements

1. 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.

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

Scheme 263

1. Connect one contact of injector to be tested to engine Ground using adapter cables from V.A.G 1594.
2. Using adapter cables connect second injector contact to remote control V.A.G 1348/3 with adapter cable V.A.G 1348/3-2.
3. Connect alligator clip to battery positive (+).
4. Switch ignition on. Fuel pump must run.

1. Operate remote control V.A.G 1348/3 for 30 seconds.
2. Repeat check on other injectors. Use another (clean and dry) measuring beaker for each.
3. After all injectors have been activated, place measuring glasses on a horizontal surface and compare quantity injected.

Specification: 85 to 105 ml per injector

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

1. Replace faulty injector
2. Erase DTC memory to return learned values to a neutral (default) position. Refer to «Engine control module Diagnostic Trouble Code (DTC) memory, interrogating and erasing»(ref-254999-S33244134722007052300000) , Interrogating and erasing DTC memory

Perform installation of injectors in reverse order. Note the following

1. Replace O-rings on all injectors and moisten then lightly with clean engine oil.
2. Insert injectors vertically and in the correct position into the fuel rail and secure with retaining clips.
3. Set fuel rail with secured injectors on intake manifold and press in evenly.

1. Engine codes AVH, AZG. Refer to «Engine control module Diagnostic Trouble Code (DTC) memory, interrogating and erasing»(ref-254999-S33244134722007052300000)
2. Engine codes BBW, BEV. Refer to «Fuel pressure regulator and holding pressure, checking»(ref-254999-S36118042952007052300000)

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

Scheme 264

Special tools and equipment

1. V.A.G 1318 Pressure gauge
2. 1318/10 Adapter
3. 1318/11 Adapter
4. 1318/16 Hose adapter

1. V.A.G 1921 Spring-type clip pliers

Requirements

1. Fuel pump delivery rate in order, checking. Refer to «Fuel Pump, Checking»(ref-254999-S41946546232007052300000)

Work sequence

Scheme 265

1. Remove supply line -1- and collect leaking fuel with a cloth.

Scheme 266

1. Connect pressure tester V.A.G 1318 with adapters V.A.G 1318/10, V.A.G 1318/11 and V.A.G 1318/6.
2. Open pressure tester shut-off valve. Handle points in through-flow direction (arrow).
3. Start engine and run at idling speed.
4. Measure fuel pressure.

Specification: approx. 2.5 bar

If specification is obtained

Scheme 267

1. Disconnect return line -1- from connection -2-. Fuel pressure must increase to approx. 3.0 bar.
2. Switch ignition off.
3. Hold pressure and check for leaks. Observe pressure drop on gauge. After 10 minutes, there must be a residual pressure of at least 2.0 bar.

If the holding pressure drops below 2 bar

1. Start engine and run at idling speed.

Scheme 268

1. Switch ignition off after pressure has built-up. At same time close pressure tester V.A.G 1318 shut-off tap (handle at right angles to through-flow direction -arrow-).
2. Observe pressure drop on gauge.

If pressure drops again

1. Check fuel pump non-return valve. Refer to «Fuel rail with injectors, disassembling and assembling»(ref-254999-S02784287142007052300000)

If pressure does not drop

1. Open shut-off tap on pressure tester V.A.G 1318 (handle point in direction of through-flow -arrow-).
2. Start engine and run at idling speed.
3. Switch ignition off once pressure has built-up and clamp off return hose at same time.

If pressure does not drop

1. Replace fuel pressure regulator. Refer to «Component locations overview»(ref-254999-S23636301912007052300000)

If pressure drops again

1. Check line connections, O-rings on fuel rail and injectors for leaks.
2. Check pressure tester for leaks.

Note. Place a cloth around the connection before removing the test pressure tester.