Volkswagen Golf Variant / Jetta. Manual - part 434

 

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Volkswagen Golf Variant / Jetta. Manual - part 434

 

 

Caution

Loosen the rail and move it slightly. This makes it possible to

mount the fuel injection line free of tension. The lines must not

be bent or under stress. Long term this would cause the line to

break.

Note

The following describes installing new fuel injection lines. If in‐

stalling fuel injection lines, which were already removed, then be

sure to check the points listed in -item 5- 

⇒ Item 5 (page 312)

 .

The procedure is otherwise identical.

Installing the Individual Fuel Injection Lines (Cylinder 1 through

4, between the Rail and Fuel Injector)
Tightening specifications. Refer to

⇒ “3.3 Overview - Fuel System”, page 311

 .

– Remove the new fuel injection line from the packaging, re‐

move the plugs and place the line between the rail and injector

immediately.

– First tighten the union nuts by hand on the fuel injection line

without using tools. Make sure the line is installed correctly.

– Proceed the same way with the other fuel injection lines, if

necessary.

– Tighten the rail, if necessary, again to the tightening specifi‐

cation.

3. Diesel Direct Injection System    

319

lines to the tightening specification using Torque Wrench 1331

5-50Nm - VAG1331- and Union Nut Socket - T40055- .

Installing the Fuel Line (between the High Pressure Pump and

the Rail) or the Entire Wiring Harness
Tightening specifications. Refer to

⇒ “3.3 Overview - Fuel System”, page 311

 .

– Loosen the bolts on the Rail and make sure it is possible to

move the rail, if this was not done before.

– Then remove the fuel line from its packaging, remove the plugs

and position the line immediately between the high pressure

pump and the rail.

– First tighten the union nuts by hand on the fuel injection line

without using tools. Make sure the line is installed correctly.

– Proceed in the same way with the four fuel injection lines, if

the entire wiring harness has to be installed.

– Install all three clamps over the fuel line. Make sure they are

aligned.

– Install the clamp screws approximately 3 thread turns.
– Tighten the rail again.
– Tighten the top clamp on the intake manifold to 8 Nm.

– Tighten the union nuts on all the newly installed fuel injection

lines to the tightening specification using Torque Wrench 1331

5-50Nm - VAG1331- and Union Nut Socket - T40055- .

– Tighten the other two clamps to 8 Nm.
– Press the return line connections carefully over the sealing

ring onto the injector (check the sealing ring first for damage).

The connection must engage audibly. Then press the release

pin down carefully.

– Fill the fuel system. Refer to

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

 .

320

Fuel Pressure Regulator Valve - N276- ,

Checking

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.

– Remove the engine cover. Refer to

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

 .

– Remove the noise insulation from the injectors.
– Disconnect the fuel return line -1-.

– Seal the open return line connection with a plug -1-.
– Connect the return line -2- with a hose -3-.

– Hold his hose -1- inside a suitable container -2- in order to

measure the return quantity.

– Start engine and let it run at idle.
• Target value in 30 seconds: 90 to 110 ml (3.0 to 3.7 ounces).
If the specified value is not attained, then the fuel pressure regu‐

lator valve is faulty.

3. Diesel Direct Injection System    

321

Fuel Pressure Regulator Valve - N276- ,

Removing and Installing

Function
The Fuel Pressure Regulator Valve - N276- is located in the rail

element (high pressure reservoir) and maintains a constant pres‐

sure in the rail element and in the high pressure lines (high

pressure fuel circuit).
If the pressure in the high pressure fuel circuit is too high, the Fuel

Pressure Regulator Valve - N276- opens so a portion of the fuel

leaves the rail element through the return line and goes back into

the fuel tank.
If the pressure in the fuel high pressure circuit is too low, the Fuel

Pressure Regulator Valve - N276- closes and seals off the high

pressure side from the low pressure side.
Special tools and workshop equipment required
♦ Torque Wrench 1332 40-200Nm - VAG1332-

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.

⇒ , page 323

 .

Removing:
– Remove the engine cover. Refer to

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

 .

– Before removing, clean the threaded area around the Fuel

Pressure Regulator Valve - N276- (for example using com‐

mercially available coolant). Contamination must not enter the

bore in the rail element (high pressure reservoir).

Note

Clean carefully, cleaner must not enter the connector.

The Fuel Pressure Regulator Valve - N276- cannot be used

again.

– Dry the Fuel Pressure Regulator Valve - N276- .

322

 

 

 

 

 

 

 

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