Volkswagen Golf / Golf Plus. Manual - part 332

 

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Volkswagen Golf / Golf Plus. Manual - part 332

 

 

Diesel direct injection system

The diesel direct injection system control unit is equipped with a

fault memory. Read fault memory before and after making repairs

or adjustments.
Safety precautions 

⇒ page 166

Rules for cleanliness 

⇒ page 167

 .

Assembly overview - unit injector 

⇒ page 167

Removing and installing unit injector 

⇒ page 169

Adjusting non-contact gap of unit injectors 

⇒ page 171

Removing and installing O-rings for unit injector 

⇒ page 172

Repairing intake manifold flap 

⇒ page 174

Assembly overview - air filter 

⇒ page 177

 .

1.1

Safety precautions

WARNING

When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to the cramped condi‐

tions:

♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐

vated charcoal filter system, coolant and refrigerant, brake

fluid and vacuum) and electrical wiring in their original po‐

sitions.

♦ Ensure that there is sufficient clearance to all moving or

hot components.

Observe following if test and measuring instruments are required

during a road test:
♦ Test and measuring instruments must be secured to rear seat

and operated by a second person from this location.

♦ If test and measuring instruments are operated from front pas‐

senger seat and the vehicle is involved in an accident, there

is a possibility that the person sitting in this seat may receive

serious injuries when the airbag is triggered.

To prevent injuries to persons and/or destruction of the injection

and glow plug system, the following must be noted:
♦ The ignition must be switched off before connecting or dis‐

connecting injection or glow plug system wiring or tester ca‐

bles.

♦ If the engine is to be turned at starter speed, without starting,

e.g. when checking compressions, disconnect unit injector

connector on cylinder head.

♦ Before disconnecting battery, obtain radio code for radios with

anti-theft coding.

♦ Disconnecting and connecting the battery must only be done

with the ignition switched off, as otherwise the control unit for

diesel direction injection system could become damaged.

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

166

     Rep. Gr.23 - Mixture preparation - injection

 

When working on fuel supply and injection system, pay careful

attention to the following rules for cleanliness:
♦ Thoroughly clean all unions and adjacent areas before dis‐

connecting.

♦ Place removed parts on a clean surface and cover. Do not use

fluffy cloths!

♦ Carefully cover opened components or seal if repairs cannot

be carried out immediately.

♦ Install clean components only. Do not remove replacement

parts from packing until immediately before installing. Do not

use parts that have not been stored in their packing (e.g. in

tool boxes etc.).

♦ When system is open: do not work with compressed air if this

can be avoided. Do not move vehicle unless absolutely nec‐

essary.

♦ Also ensure that no diesel fuel runs on to the coolant hoses.

Should this occur, the hoses must be cleaned immediately.

Damaged hoses must be renewed.

1.3

Assembly overview - unit injector

♦ Observe rules for cleanliness 

⇒ page 167

 .

♦ Always renew seals and O-rings

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

1. Diesel direct injection system    

167

 

/4 turn (90°) fur‐

ther

❑ Renew

2 - Rocker arm shaft

❑ With rocker arms
❑ Removing and installing

⇒ page 169

 .

3 - Lock nut, 30 Nm
4 - Adjuster screw

❑ Renew

5 - Ball stud

❑ Renew

6 - Unit injector

❑ Removing and installing

⇒ page 169

 .

7 - O-ring

❑ Renewing 

⇒ page 172

8 - O-ring

❑ Renewing 

⇒ page 172

9 - O-ring

❑ Renew 

⇒ page 172

 .

10 - Heat shield seal

❑ Renew

11 - Circlip
12 - Cylinder head
13 - Tensioning block
14 - 12 Nm + 

3

/4 turn (270°)

further

❑ Renew.

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

168

     Rep. Gr.23 - Mixture preparation - injection

 

Special tools and workshop

equipment required
♦ Universal dial gauge brack‐

et -VW 387-

♦ Special wrench, long reach

-3410-

♦ Special wrench, long reach

-T10054-

♦ Puller -T10055-
♦ Torque wrench -

V.A.G 1331-

1.4.1

Removing

– Remove toothed belt guard upper part.
– Remove cylinder head cover. 

⇒ page 48

– Turn crankshaft until the cam pair point evenly upwards for the

unit injector which is to be removed.

– Loosen lock nuts of adjustment screws -1- and remove ad‐

justment screws.

– Remove rocker arm securing bolts -2- (from outwards to in‐

wards) with socket XZN 10 -3410- and remove rocker arm

shaft.

– Remove tensioning block securing bolt -3- with special

wrench, long reach -T10054- and remove the block.

– Lever connector off unit injector with a screwdriver. To avoid

canting, support opposite side of connector with light finger

pressure.

Observe unit injector cylinder allocation.

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

1. Diesel direct injection system    

169

 

 

 

 

 

 

 

 

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