Volkswagen Golf Variant / Jetta. Manual - part 432

 

  Index      Volkswagen     Volkswagen Golf Variant (2007), Jetta (2005) - service repair manual

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  430  431  432  433   ..

 

 

Volkswagen Golf Variant / Jetta. Manual - part 432

 

 

⇒ “3.4 Fuel Injector (Piezo Injector), Removing and Installing”, page 315

 .

3.3

Overview - Fuel System

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.

Caution

Follow the points below to avoid running the high pressure fuel

pump dry and to start the engine quickly after replacing the

components:

♦ If the fuel system components between the fuel tank and

the high pressure fuel pump are removed or replaced,

♦ the basic setting “transfer fuel pump test” must be per‐

formed to vent the fuel system.

♦ If a fuel pump, fuel line (between the fuel tank and the high

pressure fuel pump) or fuel filter is removed or replaced,

♦ the “transfer fuel pump test” basic setting must be per‐

formed »1 time« before starting the engine for the first

time.

♦ If the high pressure fuel pump was removed or replaced,

the “check the transfer fuel pump” basic setting must be

performed »three times« before starting the engine for the

first time.

♦ Fill the fuel tank after installing the high pressure pump.

Refer to

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

 .

3. Diesel Direct Injection System    

311

❑ For the rail element

(high pressure reser‐

voir) -item 7-

⇒ Item 7 (page 313)

and high pressure lines

-item 5-

⇒ Item 5 (page 312)

2 - Fuel Return Lines

❑ With pressure retaining

valve -item 8-

⇒ Item 8 (page 308)

❑ The fuel return line must

be routed correctly.

They may be replaced

only with the pressure

retaining valve.

❑ Run the engine at idle

for approximately two

minutes after replacing

to bleed the fuel system

and then check the fuel

return lines for leaks.

❑ Pressure Retention

Valve in Fuel Return

Line, Checking. Refer to

⇒ “3.11 Pressure Re‐

taining Valve in Fuel Re‐

turn, Checking”,

page 330

 .

3 - Bolt

❑ 8 Nm

4 - Fuel Return Line

❑ Blue or with blue mark‐

ing

❑ Check for secure fit
❑ From fuel filter -item 7- 

⇒ Item 7 (page 250)

5 - High Pressure Lines

❑ 28 Nm
❑ Between the rail element (high pressure reservoir) -item 7- 

⇒ Item 7 (page 313)

 and fuel injector

-item 20- 

⇒ Item 20 (page 313)

Caution

The  high  pressure  lines

can be reused only after

the following tests:

Check the sealing cone

on each high pressure

line for the deformation

and cracks.

The holes for the lines

must not be deformed,

narrowed or damaged.

Do not use corroded lines

again.

❑ Do not interchange
❑ When installing, the fuel injectors -item 20- 

⇒ Item 20 (page 313)

 and high pressure lines may only be

installed on the same cylinder as before.

312

6 - Fuel Pressure Regulator Valve - N276- , 80 Nm

❑ Removing and installing. Refer to

⇒ “3.6  Fuel Pressure Regulator Valve N276 , Removing and Installing”, page 322

 .

7 - Rail Element (High Pressure Reservoir)
8 - Fuel Temperature Sensor - G81-
9 - Fuel Supply Line

❑ Check for secure fit
❑ Between the Fuel Temperature Sensor - G81- -item 8- 

⇒ Item 8 (page 313)

 and high pressure fuel pump

-item 10- 

⇒ Item 10 (page 313)

 .

10 - High Pressure Fuel Pump

❑ With Fuel Metering Valve - N290- -item 1- 

⇒ Item 1 (page 308)

❑ Removing and installing. Refer to

⇒ “3.8 High Pressure Fuel Pump, Removing and Installing”, page 325

 .

❑ The fuel system “must” always be filled after replacing (never run dry) (refer to

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

 ), Fuel System, Filling.

11 - Bolt

❑ 20 Nm

12 - Bracket

❑ For the Fuel Temperature Sensor - G81- -item 8- 

⇒ Item 8 (page 313)

13 - Fuel Supply Line

❑ white or with white markings
❑ Check for secure fit
❑ From the Auxiliary Fuel Pump - V393-
❑ Auxiliary Fuel Pump - V393- , Removing and installing. Refer to

⇒ “6.6  Auxiliary Fuel Pump V393 (Inline Fuel Pump), Removing and Installing”, page 259

14 - Fuel Pressure Sensor - G247- , 100 Nm

❑ Removing and installing. Refer to

⇒ “3.7  Fuel Pressure Sensor G247 , Removing and Installing”, page 323

 .

15 - Bolt

❑ 22 Nm

16 - Tensioning Claw

❑ Replace
❑ Note the installation position Refer to 

⇒ Fig. ““Tensioning Bracket Installation Position”“ , page 314

 .

17 - Nut

❑ 10 Nm

18 - Fuel Injector Cover
19 - Bolt

❑ 5 Nm

20 - Fuel Injector (Piezo Injector)

❑ The following components and seals and/or O-ring must be replaced at every removal and installation:

“tension bracket”, “copper washer”, “fuel injection unit shaft O-ring” and “fuel injection return O-ring”.

❑ The following components and seals and/or O-ring must be replaced when replacing the fuel injection

unit: “tensioning claw”, “fuel injection line”, “copper washer” “fuel injection unit shaft O-ring” “fuel injection

unit return O-ring”

❑ When installing, the fuel injectors -item 5- 

⇒ Item 5 (page 312)

 and high pressure lines may only be

installed on the same cylinder as before.

❑ Removing and installing. Refer to

⇒ “3.4 Fuel Injector (Piezo Injector), Removing and Installing”, page 315

 .

3. Diesel Direct Injection System    

313

❑ 28 Nm
❑ between the high pressure fuel pump -item 10- 

⇒ Item 10 (page 313)

 and rail element (high pressure

reservoir) -item 7- 

⇒ Item 7 (page 313)

Caution

The  high  pressure  lines

can be reused only after

the following tests:

Check the sealing cone

on each high pressure

line for the deformation

and cracks.

The holes for the lines

must not be deformed,

narrowed or damaged.

Do not use corroded lines

again.

❑ Do not bend the high pressure line to a different angle.
❑ Install without tension

Tensioning Bracket Installation Position

314

 

 

 

 

 

 

 

Content   ..  430  431  432  433   ..