Volkswagen Golf Variant / Jetta. Manual - part 435

 

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Volkswagen Golf Variant / Jetta. Manual - part 435

 

 

Valve - N276- -arrow-.

– Counterhold at the housing hex bolt and loosen the union nut.

Then remove it by hand.

– Extract the contamination from the rail element bore (threads

and sealing surface). Do not use mechanical tools.

Note

Seal the rail element bore immediately with a suitable plug to pre‐

vent contaminants from entering.

Installing:

Note

Check the Fuel Pressure Regulator Valve - N276- sealing sur‐

face and threads for damage.

Check the sealing surface on the rail element bore.

The threads on the Fuel Pressure Regulator Valve - N276-

must be free of oil and grease.

– First tighten the union nut on the Fuel Pressure Regulator

Valve - N276- by hand.

– Align the Fuel Pressure Regulator Valve - N276- so the con‐

necting line is not taut after connecting the electrical connec‐

tor.

– Counterhold at the housing hex bolt and tighten the union nut:
• Tightening specification -item 6- 

⇒ Item 6 (page 313)

 .

– After installing, let the engine run at a moderate speed for a

few minutes and then stop it.

– Check the fuel system for leaks. Refer to

⇒ “3.10 Fuel System, Performing Leak Test”, page 329

 .

– Read the DTC memory for the Engine Control Module - J623-

again. Refer to Vehicle Diagnostic Tester in “Guided Func‐

tions”.

– Install the engine cover. Refer to

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

 .

3.7

Fuel Pressure Sensor - G247- , Remov‐

ing and Installing

Function
The Fuel Pressure Sensor - G247- (rail pressure sensor) is loca‐

ted in the rail element (high pressure reservoir). It measures the

current fuel pressure in the high pressure system and delivers a

voltage signal to the Engine Control Module - J623- .
If the Fuel Pressure Sensor - G247- malfunctions, the pressure is

controlled via an Engine Control Module - J623- characteristic

map (maximum engine speed is limited to approximately 3000

RPM in emergency operation mode).
Special tools and workshop equipment required
♦ Torque Wrench 1332 40-200Nm - VAG1332-

3. Diesel Direct Injection System    

323

♦ 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.

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 Sensor - G247- (for example using commercially

available coolant). Contamination must not enter the bore in

the rail element (high pressure reservoir).

Note

Clean carefully, cleaner must not enter the connector.

– Dry the Fuel Pressure Sensor - G247- .

324

G247- -C-.

– Remove the Fuel Pressure Sensor - G247- .
– Extract the contamination from the rail element bore (threads

and sealing surface). Do not use mechanical tools.

Note

Seal the rail element bore immediately with a suitable plug to pre‐

vent contaminants from entering.

Installing:

Note

Check the Fuel Pressure Sensor - G247- sealing surface and

threads for damage.

Check the sealing surface on the rail element bore.

The Fuel Pressure Sensor - G247- threads are coated with an

anti-friction coating so they must be free of oil and grease.

– First tighten the Fuel Pressure Sensor - G247- by hand.
– Tighten the Fuel Pressure Sensor - G247- :
• Tightening specification -item 14- 

⇒ Item 14 (page 313)

 .

– After installing, let the engine run at a moderate speed for a

few minutes and then stop it.

– Check the fuel system for leaks. Refer to

⇒ “3.10 Fuel System, Performing Leak Test”, page 329

 .

– Read the DTC memory for the Engine Control Module - J623-

again. Refer to Vehicle Diagnostic Tester in “Guided Func‐

tions”.

– Install the engine cover. Refer to

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

 .

3.8

High Pressure Fuel Pump, Removing

and Installing

Special tools and workshop equipment required
♦ Counterhold - Camshaft Gear - T10051-
♦ Union Nut Socket - T40055-
♦ Puller - Pulley - T40064-
♦ Puller - Pulley - Pressure Pad - T40064/1-
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Torque Wrench 1331 Insert - Reversible Ratchet -

VAG1331/1-

♦ Hose Clip Pliers - VAS6362-
♦ Engine Bung Set - VAS6122- (not illustrated)

3. Diesel Direct Injection System    

325

♦ 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.

Removing:
Requirements
• Ignition switched off.
• Engine must be cold.

Note

Only remove the high pressure fuel pump when the engine is

cold.

Make sure no contaminants enter the fuel system when re‐

moving the high pressure fuel pump.

Seal off the connections in the fuel system using the plugs from

the Engine Bung Set - VAS6122- .

Procedure
– Remove the toothed belt from the camshaft and the high pres‐

sure fuel pump. Refer to

⇒ “1.6 Toothed Belt, Removing, Installing and Tensioning”,

page 95

 , Toothed Belt, Removing, Installing and Tensioning.

– Disconnect from the Fuel Temperature Sensor - G81- -1- and

from the Fuel Metering Valve - N290- on the high pressure fuel

pump -2-.

– Loosen the spring clips -3 and 4- with the Hose Clip Pliers -

VAS6362- and disconnect the fuel lines at the high pressure

fuel pump.

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

326

 

 

 

 

 

 

 

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