Volkswagen Golf Variant / Jetta. Manual - part 430

 

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Volkswagen Golf Variant / Jetta. Manual - part 430

 

 

1

Safety Precautions when Working on

Diesel Direct Fuel Injection System

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.

DANGER!

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

partment,  pay  attention  to  the  following  due  to  the  limited

space.

♦ The fuel or fuel lines in fuel system can become very hot

(danger of scalding)!

♦ Always wear protective eyewear, safety gloves and pro‐

tective clothing when performing any work on the fuel

system to avoid eye injuries and burns.

♦ In addition, the fuel system is under pressure! Before

opening the system, place rags around the connection

area and release pressure by carefully loosening the con‐

nection!

♦ If fuel system components between the fuel tank and high

pressure fuel pump were removed or replaced, the fuel

system must be filled in order to bleed it. Refer to

⇒ “3.9 Fuel System, Filling/Bleeding”, page 328

 . (Run‐

ning the high pressure fuel pump when dry must always

be avoided).

If Testing Equipment Is Required during a Road Test, Note the

Following:
♦ Test and measuring instruments must be secured to rear seat

and operated by a second person from this location.

If the vehicle is involved in a collision while testing and measuring

equipment is operated from the front passenger seat, the person

sitting in that seat could be seriously injured when the airbag de‐

ploys.
To Reduce the Risk of Personal Injury and/or Damage to the Fuel

Injection and Glow Plug System, Always Observe the Following:
♦ Only disconnect and reconnect wires for glow plug and fuel

injection systems, including test leads, when the ignition is

switched off.

1. Safety Precautions when Working on Diesel Direct Fuel Injection System    

303

when the ignition is switched off, otherwise it could damage

the Engine Control Module - J623- .

– Observe the notes after connecting the Battery - A- . Refer to

⇒  Electrical Equipment; Rep. Gr.  27 ; Battery; Battery, Dis‐

connecting and Connecting .

304

Guidelines for Clean Working Condi‐

tions

When Working on the Fuel Supply/Injection System, Pay Careful

Attention to the Following “7 rules” of Cleanliness:
♦ Thoroughly clean the connection points and the surrounding

area before loosening.

♦ Place the removed parts on a clean surface and cover them.

Only use lint-free cloths.

♦ Carefully cover or seal opened components if the repair is not

performed immediately.

♦ Only install clean parts: remove the replacement parts from

their packaging just before installing them. Do not use parts

that have been loosely stored or unpackaged (for example, in

tool boxes etc.).

♦ Transport and protective packaging and sealing caps are to

be removed only immediately prior to installation.

♦ When the fuel system is open: avoid working with compressed

air if possible. Do not move the vehicle if possible.

♦ In addition, do not let diesel fuel flow onto the coolant hoses.

If necessary, the hoses must be cleaned again immediately.

Replace corroded hoses.

2. Guidelines for Clean Working Conditions    

305

Diesel Direct Injection System

⇒ “3.1 General Information”, page 306
⇒ “3.2 System Overview”, page 307
⇒ “3.3 Overview - Fuel System”, page 311
⇒ “3.4 Fuel Injector (Piezo Injector), Removing and Installing”,

page 315
⇒ “3.5  Fuel Pressure Regulator Valve N276 , Checking”,

page 321
⇒ “3.6  Fuel Pressure Regulator Valve N276 , Removing and In‐

stalling”, page 322
⇒ “3.7  Fuel Pressure Sensor G247 , Removing and Installing”,

page 323
⇒ “3.8 High Pressure Fuel Pump, Removing and Installing”, page

325
⇒ “3.9 Fuel System, Filling/Bleeding”, page 328
⇒ “3.10 Fuel System, Performing Leak Test”, page 329
⇒ “3.11 Pressure Retaining Valve in Fuel Return, Checking”, page

330
⇒ “3.12 Overview - Intake Manifold with Attachments”,

page 331
⇒ “3.13 Intake Manifold, Removing and Installing”, page 333
⇒ “3.14 Overview - Air Filter”, page 335
⇒ “3.15 Air Filter Housing, Removing and Installing”, page 338
⇒ “3.16 Air Filter Element, Removing and Installing”, page 339
⇒ “3.17  Mass Airflow Sensor G70 , Removing and Installing”,

page 341

3.1

General Information

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.

Note

The Engine Control Module - J623- is equipped with a DTC mem‐

ory. Before and after repairs or adjustments, the DTC memory

must be checked. Refer to Vehicle Diagnostic Tester in “Guided

Functions”.

306

 

 

 

 

 

 

 

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