Home ReviewsRefund
Home/Volkswagen/Passat/Volkswagen Passat B5 (1996-2001)/Repair manual/2.8L V6 5V Engine Mechanical, Fuel Injection Ignition, Engine Codes: Aha, Atq/Components, checking
Contents Wiring diagrams Section: 2.8L V6 5V Engine Mechanical, Fuel Injection Ignition, Engine Codes: Aha, Atq All sections

Components, checking Volkswagen Passat B5

2.8L V6 5V Engine Mechanical, Fuel Injection Ignition, Engine Codes: Aha, Atq 9 illustrations ~922 words

Components, checking

Checking injection quantity and proper seal of fuel injectors --> Fuel injectors, injection quantity and checking for leaks

Fuel pressure regulator and residual pressure, checking --> Fuel pressure regulator and residual pressure, checking

Scheme 491

Scheme 491: Fuel injectors, injection quantity and checking for leaks
Scheme 491: Fuel injectors, injection quantity and checking for leaks

Special tools, testers and auxiliary items required

  1. Remote control connection V.A.G 1348/3
  2. Adapter V.A.G 1348/3-2
  3. Injector quantity testing device V.A.G 1602
  4. Connector test set V.A.G 1594C

Conditions

  1. Fuel pressure must be OK, checking --> «Fuel pressure regulator and residual pressure, checking»(ref-255333-S04124968762007053000000) .

Work sequence

  1. Remove intake manifold cover.
  2. Remove intake air hose between Mass Air Flow (MAF) sensor and intake air scoop.

Scheme 492

Scheme 492
Scheme 492
  1. Disconnect connectors - 1 - from connections - 2 - on all fuel injectors.

Scheme 493

Scheme 493
Scheme 493
  1. Remove fuel rail from intake manifold - arrows -.
  2. Disconnect vacuum hose from fuel pressure regulator.
  3. Lift fuel rail with injectors off intake manifold and support it.

Checking for leaks

  1. Initiate output diagnostic test mode using vehicle diagnosis, testing and information system VAS 5051 --> «Adapting functions and components»(ref-255333-S01715979652007053000000) ; Fuel pump must run.

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

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

If fuel loss is greater

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

Checking Injection Quantity

Scheme 494

Scheme 494
Scheme 494
  1. Place a fuel injector to be tested into a graduated measuring glass of injection quantity test device V.A.G 1602.

Scheme 495

Scheme 495
Scheme 495
  1. Connect one terminal of fuel injector to be checked to engine Ground (GND) using adapter cables from connector test kit V.A.G 1594C.
  2. Connect second fuel injector terminal with adapter cable to remote control V.A.G 1348/3 using adapter cable V.A.G 1348/3-2.
  3. Connect alligator clip to battery positive (+).
  4. Initiate output diagnostic test mode using vehicle diagnosis, testing and information system VAS 5051 --> «Adapting functions and components»(ref-255333-S01715979652007053000000) ; Fuel pump must run.

Note. This work step allows the fuel pump to run when the engine is not running. During the following check of injection quantity, also check the spray pattern. Spray pattern must be the same for all fuel injectors.

  1. Operate remote control V.A.G 1348/3 for 30 seconds.
  2. Repeat check on other injectors. Use a new graduated measuring glass for each.
  3. After all fuel injectors have been activated, place graduated measuring glasses on a level surface and compare quantity of injected fuel.
  4. Specification: 90 to 125 ml per injector

If measured value of one or more fuel injectors is below or above the indicated specified value

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

When installing fuel injector, observe the following

  1. Replace O-rings on all injectors and lightly moisten with clean engine oil.
  2. Insert fuel injectors into fuel rail perpendicular and in correct position, and secure them with retaining clips.
  3. Position fuel rail with secured fuel injectors on intake manifold and apply uniform pressure to press it in.
  1. Check Diagnostic Trouble Code (DTC) memory of Engine Control Module (ECM), repair any stored malfunctions and then erase DTC memory --> «Engine Control Module (ECM) Diagnostic Trouble Code (DTC) memory, checking and erasing»(ref-255333-S02988447012007053000000) .

Scheme 496

Scheme 496: Fuel pressure regulator and residual pressure, checking
Scheme 496: Fuel pressure regulator and residual pressure, checking

Special tools, testers and auxiliary items required

  1. Pressure gauge V.A.G 1318
  2. Adapter V.A.G 1318/7
  3. Adapter V.A.G 1318/10
  4. Hose adapter V.A.G 1318/13

Function

The fuel pressure regulator controls the fuel pressure and is dependent on intake manifold pressure.

Conditions

  1. Delivery quantity of Fuel Pump (FP) OK; checking --> «Fuel pump, checking»(ref-255333-S30813134452007053000000) .

Work sequence

  1. Remove fuse 28 for Fuel Pump (FP) from fuse holder.
CAUTIONFuel supply lines are under pressure! Wear eye protection and protective gloves to avoid injuries and skin contact with fuel. Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.
  1. Disconnect fuel supply hose - 1 - from fuel rail - 2 - (counterhold on hex of fuel rail).

Scheme 497

Scheme 497
Scheme 497
  1. Connect pressure tester V.A.G 1318 with adapter V.A.G 1318/7, adapter V.A.G 1318/10 and adapter V.A.G 1318/13 as shown.
  2. Open shut-off valve on pressure gauge. The lever points in the direction of flow - arrow -.
  3. Install fuse 28 (fuel pump) into fuse holder.
  4. Start engine and run at idle speed.
  1. Measure fuel pressure.
  2. Specification: about 3.5 bar positive pressure

Scheme 498

Scheme 498
Scheme 498
  1. Pull vacuum hose off of fuel pressure regulator - arrow -.
  2. Fuel pressure must rise to approx. 4.0 bar positive pressure.

Note. If fuel drips from the vacuum connection of the fuel pressure regulator, replace fuel pressure regulator.

  1. Switch off ignition.
  2. Check for leaks and residual pressure. Observe pressure drop on pressure gauge. After 10 minutes there must be a residual pressure of at least 2.0 bar.

If the residual pressure drops below 2 bar

  1. Start engine and run at idle speed.

Scheme 499

Scheme 499
Scheme 499
  1. Wait until pressure has built up, then switch off ignition. Simultaneously close shut-off valve of pressure gauge V.A.G 1318 (lever perpendicular to direction of flow - arrow - ).
  2. Watch pressure drop on gauge.

If pressure does not drop

  1. Test check valve of fuel pump.

If pressure drops again

  1. Open shut-off tap on pressure gauge V.A.G 1318 (lever in through flow direction - arrow - ).
  2. Start engine and run at idle speed.
  3. Wait until pressure has risen, and then switch off ignition. At same time pinch return hose - 3 - tightly together.

If pressure does not drop

  1. Replace fuel pressure regulator.

If pressure drops again

  1. Check whether line connections, O-rings in fuel distributor, and fuel injectors are properly sealed.
  2. Check pressure gauge for proper seal.

Assembly is performed in the reverse order of removal. Also observe the following

  1. Before removing pressure gauge V.A.G 1318, remove fuse No. 28 and put cleaning rags back around line connection which is to be disconnected.
  2. Fasten fuel supply hose to fuel rail