Volkswagen Golf Variant / Jetta. Manual - part 437

 

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Volkswagen Golf Variant / Jetta. Manual - part 437

 

 

cloth.

– Remove the fuel return line connection from cylinder 1. Press

the connection at the tabs -2- downward and pull the center

piece -1- upward to release.

Note

Pay attention to cleanliness. Dirt must not enter the return line and

the connection on the fuel injectors.

– Install the Fuel Return System Tester - VAS6330- between the

return line connection on the fuel injector and the return line.

– Start the engine and let it run at idle speed.
– Check the pressure on the pressure gauge.
• Specified value: approximately 10 bar (145.03 psi)
If the specified value is not obtained:
– Replace the pressure retaining valve -item 8-

⇒ Item 8 (page 308)

 .

3.12

Overview - Intake Manifold with Attach‐

ments

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.

3. Diesel Direct Injection System    

331

❑ With Intake Flap Motor -

V157-

❑ With intake air swirl op‐

timization

❑ Must not be disassem‐

bled

❑ Removing and instal‐

ling. Refer to

⇒ “3.13 Intake Manifold,

Removing and Instal‐

ling”, page 333

2 - Bolt

❑ 8 Nm

3 - Seal

❑ Replace

4 - Seal

❑ Replace

5 - Connecting Pipe

Caution

Make sure the connect‐

ing pipe decoupling ele‐

ment  does  not  bend  or

stretch. Cracks could de‐

velop.

❑ Replace
❑ Install without tension

6 - Bolt

❑ 20 Nm
❑ Use the Socket - Xzn 10

- T10385- for loosening and tightening

7 - Seal

❑ Replace

8 - Bolt

❑ 8 Nm

9 - Throttle Valve Control Module - J338-

❑ For removal, remove the intake manifold. Refer to

⇒ “3.13 Intake Manifold, Removing and Installing”, page 333

 .

10 - Bolt

❑ 8 Nm
❑ Refer to 

⇒ Fig. ““”“ , page 335

❑ Removing and installing with the Socket - Xzn 8 - T40159-

11 - Bolt

❑ 8 Nm
❑ Removing and installing with the Socket - Xzn 8 - T40159-

12 - Oil Dipstick

❑ Engine Oil Level, Checking. Refer to 

⇒ “1.2 Engine Oil, Checking Level”, page 151

 .

332

❑ With the EGR Potentiometer - G212-

3.13

Intake Manifold, Removing and Instal‐

ling

Special tools and workshop equipment required
♦ Socket - Xzn 10 - T10385-
♦ Socket - Xzn 8 - T40159-
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Hose Clip Pliers - VAS6362-
♦ Torque Wrench 1331 Insert - Reversible Ratchet -

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.

Removing:

Note

Make sure no contaminants enter the fuel system when re‐

moving the intake manifold.

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

the Engine Bung Set - VAS6122- .

– Remove the engine cover. Refer to

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

 .

– Remove the protective strip, if equipped -item 1-

⇒ Item 1 (page 312)

 .

– Loosen the high pressure line or fuel lines -arrows- on the in‐

take manifold.

3. Diesel Direct Injection System    

333

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 high pressure line -item 21-

⇒ Item 21 (page 314)

 between the high pressure fuel pump

and rail element (high pressure reservoir).

– Loosen the hose clip -arrow- with the Hose Clip Pliers -

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).

– Dry the return line connections.
– 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 -arrow-.

Note

Pay attention to cleanliness. Dirt and contaminants must not enter

the return lines and the connections on the fuel injectors.

– Loosen the hose clips 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 lines -item 2- 

⇒ Item 2 (page 312)

 .

334

 

 

 

 

 

 

 

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