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