Volkswagen Golf Variant / Jetta. Manual - part 377

 

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Volkswagen Golf Variant / Jetta. Manual - part 377

 

 

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VAG1331/1-

♦ Engine Bung Set - VAS6122-

DANGER!

♦ Follow the safety precautions when working on the diesel

direct fuel injection system. Refer to

⇒ “1 Safety Precautions when Working on Diesel Direct

Fuel Injection System”, page 303

 .

♦ Pay attention to the guidelines for clean working condi‐

tions. Refer to

⇒ “2 Guidelines for Clean Working Conditions”,

page 305

 .

Always pay attention to these instructions before and during

work.

WARNING

When doing any assembly work, especially in the engine com‐

partment,  pay  attention  to  the  following  due  to  the  limited

space.

♦ Route all lines and wires in their original locations.
♦ For example, for fuel lines, hydraulic lines, EVAP system

lines, coolant and refrigerant lines, brake fluid lines and

vacuum lines.

♦ Make sure that there is sufficient clearance to all moving

or hot components.

Removing
– Remove the engine cover. Refer to

⇒ “1.4 Engine Cover, Removing and Installing”, page 90

 .

– Remove the protective strip -item 3- 

⇒ Item 3 (page 83)

 .

– Disconnect from the fuel injectors -A-, the Exhaust Pressure

Sensor 2 - G451- -B- and the Fuel Pressure Sensor - G247-

-C-.

– Remove the coolant line bolts -arrows- from the intake mani‐

fold and lay the line in front of the intake manifold.

– Unclip the wiring harness from the wiring guide for the glow

plugs.

Caution

Always follow the procedure »Glow Plug Connectors, Remov‐

ing and Installing«.

– Remove the glow plug connectors. Refer to

⇒ “1.3 Glow Plug Connectors, Removing and Installing”, page

410

 .

– Remove the fuel return line bolt -item 3-

⇒ Item 3 (page 312)

 on the intake manifold.

1. Cylinder Head    

91

VAS6362- and remove the line on the rail element (high pres‐

sure reservoir).

– Before removing, clean the return line connection on the fuel

injectors (for example using a commercially available deter‐

gent).

– Cover the return line connections with a cleaning cloth.

– Remove the fuel return line connections on the fuel injectors.

Pull them upward to release them in direction of -arrow-.

Note

Follow the rules of cleanliness.

Do not let any dirt to get into the disconnected return lines or

into the connections for the fuel injectors.

– Loosen the spring clamp with the Hose Clip Pliers - VAS6362-

and remove the fuel return line -item 4-

⇒ Item 4 (page 312)

 .

– Loosen the spring clamp -4- with the Hose Clip Pliers -

VAS6362- and disconnect the fuel return line at the high

pressure fuel pump.

– Seal the lines so that no dirt can enter the fuel system.

– Remove the fuel return line -item 2- 

⇒ Item 2 (page 312)

 and

lay them in front of the intake manifold.

– Disconnect from the Charge Air Pressure Actuator Position

Sensor - G581- -arrow- at the turbocharger vacuum dia‐

phragm and guide the line out of the holders.

92

Valve - N276- -arrow-.

– Remove the wiring guide on the rail elements (high pressure

reservoir) and move to the side.

– Remove the vacuum hose -item 11- 

⇒ Item 11 (page 84)

 from

the cylinder head cover.

– Remove the remaining vacuum hoses from the bracket on the

cylinder head cover.

– Disconnect the connector -1- from the Engine Coolant Tem‐

perature Sensor on Radiator Outlet - G83- , open the clamps

-arrows- and remove the toothed belt guard upper section.

– Remove the crankcase ventilation hose between the intake

scoop and the cylinder head cover.

Note

The crankcase ventilation hose is destroyed when it is removed.

– Remove the high pressure line -item 21-

⇒ Item 21 (page 314)

 between the high pressure fuel pump

and rail element (high pressure reservoir).

– Remove the high pressure lines -item 5-

⇒ Item 5 (page 312)

 between the rail element (high pressure

reservoir) and the fuel injectors.

– Remove the bolts -arrows- and remove the rail element (high

pressure reservoir).

– Remove the fuel injectors. Refer to

⇒ “3.4 Fuel Injector (Piezo Injector), Removing and Installing”,

page 315

 .

1. Cylinder Head    

93

-7 to 1-.

– Remove the cylinder head cover.
Installing:

Note

The plastic protectors installed to protect the open valves must

only be removed just before mounting the cylinder head.

When replacing the cylinder head or cylinder head gasket, all

of the coolant must be replaced.

Cylinder heads with cracks between the valve seats can con‐

tinue to be used without reducing service life, as long as the

tears have a width of maximum 0.5 mm.

After working on the valvetrain and engine, carefully rotate by

hand at least two full turns to be sure that valves do not strike

pistons when starting.

Always replace the self-locking nuts, seals, gaskets and

clamps.

Install in reverse order of removal. Note the following:
• Replace the cylinder head cover gasket if damaged or leaking.

Refer to Parts Catalog.

• When installing the high pressure line or fuel lines, make sure

no dirt enters the fuel system.

• Only remove the plugs right before installing the fuel lines.
• Do not change the angles of the high pressure lines
• Make sure the line connections are secure.
• Do not interchange the supply line and the return line.

– First hand-tighten the cylinder head cover bolts in the se‐

quence -1 to 7-.

– Then tighten the cylinder head cover bolts in the sequence

-1 to 7-.

• Tightening specification -item 14- 

⇒ Item 14 (page 84)

 .

– Install the toothed belt guard upper section.

94

 

 

 

 

 

 

 

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