Volkswagen Golf Variant / Jetta. Manual - part 356

 

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Volkswagen Golf Variant / Jetta. Manual - part 356

 

 

– Disconnect the connector for the Exhaust Gas Temperature

Sensor 2 - G448- -1-, the »black« connector for Exhaust Gas

Temperature Sensor 1 - G235- -2- as well as the connector for

the Heated Oxygen Sensor - G39- -3- on the plenum chamber

bulkhead.

– Disconnect the connector for the Exhaust Gas Temperature

Sensor 3 - G495- -1- (attached behind the bracket).

– Disconnect the connector -2- from the Exhaust Pressure Sen‐

sor 2 - G451- -1-.

– Remove the bolt -4- and the bracket -3- with the Exhaust Pres‐

sure Sensor 2 - G451- -1- in the direction of -arrow- and set

aside (control lines remain connected).

– Unbutton the heat shield and disconnect the connector from

the Exhaust Pressure Sensor 1 - G450- . Refer to

⇒ “1.2 Overview - Particulate Filter with NOx Reduction Cat‐

alytic Converter”, page 360

 .

– Disconnect the control wire from the Exhaust Pressure Sensor

1 - G450- . Loosen the spring clamp using the Hose Clip Pliers

- VAS6362- .

– Remove the bolts and bracket with the Exhaust Pressure Sen‐

sor 1 - G450- and lay them aside (the control wire to the

particulate filter remains connected).

– Rotate the Wastegate Bypass Regulator Valve - N75- out of

the holder and set it on the engine.

1. Engine, Removing and Installing    

7

fluid reservoir filler tube to the side.

– Remove the coolant reservoir and set it on the engine (coolant

hoses stay connected).

– Remove the fuel filter. Refer to

⇒ “6.3 Fuel Filter, Removing and Installing”, page 251

 .

– Remove the Auxiliary Fuel Pump - V393- . Refer to

⇒ “6.6  Auxiliary Fuel Pump V393 (Inline Fuel Pump), Remov‐

ing and Installing”, page 259

 .

– Disconnect the vacuum hose from the brake booster.
– Remove the noise insulation. Refer to ⇒  Body Exterior; Rep.

Gr.  50 ; Noise Insulation .

– Drain the coolant. Refer to

⇒ “1.9 Coolant, Draining and Filling”, page 209

 .

– Disconnect the coolant hoses between the engine and radia‐

tor. Refer to

⇒ “1.1 Overview - Cooling System Components, Body Side”,

page 190

 , Overview - Body Side Cooling System Compo‐

nents.

– Open the quick-release couplings for the heat exchanger

-arrows- on the plenum chamber bulkhead.

Note

Catch leaking coolant with the Drip Tray - VAS6208- .

– Disconnect the connecting hoses between the engine and the

charge air cooler. Refer to

⇒ “4.2 Overview - Charge Air Cooler Components”,

page 290

 , Overview - Charge Air Cooler Components

– Extract the refrigerant from the A/C system. Refer to ⇒  Heat‐

ing, Ventilation and Air Conditioning; Rep. Gr.  87 .

– Remove the refrigerant lines on the A/C compressor and con‐

denser and secure them on the body without tension. Refer to

⇒  Heating, Ventilation and Air Conditioning; Rep. Gr.  87 .

– Remove the lock carrier. Refer to ⇒  Body Exterior; Rep. Gr. 

50 ; Lock Carrier; Lock Carrier with Attachments, Removing

and Installing .

8

⇒  Suspension, Wheels, Steering; Rep. Gr.  40 ; Drive Axles,

Removing and Installing .

Caution

The  decoupling  elements  between  the  particulate  filter  and

NOx reduction catalytic converter can be damaged. When re‐

moving and installing:

♦ Do not bend the decoupling element more than 10°.
♦ Do not stretch the decoupling element.
♦ Do not damage the wire mesh on the decoupling element.
♦ Use the Transportation Lock - T10404- to secure the de‐

coupling element from stretching.

– Remove the lower bracket for the particulate filter.
– Remove the exhaust gas recirculation filter -item 9-

⇒ Item 9 (page 399)

 .

Note

Remove the nuts above the bracket with the Wrench - Sw13 -

T10384- .

– Remove the screw -arrow- on the top bracket for the particu‐

late filter. Loosen the bracket on the cylinder head.

– Loosen the clamp -1- between the particulate filter and the

turbocharger.

– Secure the particulate filter without tension on the body.
Vehicles with Manual Transmission:
– Remove the shift mechanism from the transmission. Refer to

⇒  6-Speed Manual Transmission 02Q; Rep. Gr.  34 .

1. Engine, Removing and Installing    

9

Hose Clamps - Up To 25mm - 3094- .

– Remove the clamp -arrow- for the hydraulic clutch hydraulic

line -A- all the way.

– Pull the hydraulic line -A- out of the breather/slave cylinder and

seal it off.

Caution

Do not operate clutch pedal any more.

Vehicles with DSG

®

 Transmission:

– Disconnect the selector lever cable from the transmission. Re‐

Continuation for All Vehicles:
– Remove/disconnect all wires necessary from engine/trans‐

mission and free them up.

Note

Verify that all hose and line/wire connections between the engine,

transmission and body have been disconnected.

– Remove the bolts -1 to 3- and then remove the pendulum sup‐

port.

10

 

 

 

 

 

 

 

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