Volkswagen Golf Variant / Jetta. Manual - part 456

 

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Volkswagen Golf Variant / Jetta. Manual - part 456

 

 

♦ Chain Pipe Cutter - VAS6254-

♦ Not Illustrated:
♦ EGR Temp. Sensor Socket - 14mm - T10401-

5. Special Tools    

407

1

Glow Plugs

⇒ “1.1 General Information”, page 408
⇒ “1.2 Glow Plug, Removing and Installing”, page 408
⇒ “1.3 Glow Plug Connectors, Removing and Installing”,

page 410

1.1

General Information

Note

The Engine Control Module - J623- is equipped with a DTC mem‐

ory. Before and after repairs or adjustments, the DTC memory

must be checked. Refer to Vehicle Diagnostic Tester “Guided

Fault Finding”.

1.2

Glow Plug, Removing and Installing

Special tools and workshop equipment required
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Engine Bung Set - VAS6122- (not illustrated)
♦ Hose Clip Pliers - VAS6362-
♦ Glow Plug Socket - VAS6454-

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

Note

When removing the glow plugs, make sure no contaminants

enter the fuel system and the glow plug duct.

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

the Engine Bung Set - VAS6122- .

408

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

 .

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

⇒ Item 1 (page 312)

 .

– Disconnect from the fuel injectors -A-, the Exhaust Pressure

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.

– Remove the fuel return line bolt -item 3- 

⇒ Item 3 (page 312)

on the intake manifold.

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

 .

– 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 in direction of -arrow-.

Note

Pay attention to cleanliness. Dirt and contaminants must not enter

the return lines and the connections on the fuel injectors.

– Loosen the spring clamp with the Hose Clip Pliers - VAS6362-

and remove the fuel return line -item 4- 

⇒ Item 4 (page 312)

 .

1. Glow Plugs    

409

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)

 and

lay them in front of the intake manifold.

– Remove the glow plug wiring guide and lay it aside.

Caution

♦ When cleaning the glow plug duct, make sure no contam‐

inants or cleaning solutions enter the connector contacts

on the glow plugs.

♦ Do not clean the connectors with cleaning solutions or

compressed air.

– Clean the glow plug duct in the cylinder head (contaminants

must not fall into the cylinder).

Note

Extract large contaminants with a vacuum cleaner.

Clean glow plugs with a commercially available detergent.

Dry the glow plugs with compressed air.

Then clean the glow plug duct with a rag dampened with oil.

– Remove the glow plugs with the Glow Plug Socket -

VAS6454- .

Installing:
Install in reverse order of removal. Note the following:
• When installing the glow plugs, make sure no contaminants

enter the fuel system and the glow plug duct.

• Only remove the sealing plugs right before installing the fuel

return lines.

• Make sure the line connections are secure.
– Tighten the glow plugs with the Glow Plug Socket - VAS6454- .
• Tightening specification: 12 Nm.
– Secure the fuel return line to the intake manifold.
• Tightening specification -item 3- 

⇒ Item 3 (page 312)

 .

– Install the glow plug connectors. Refer to

⇒ “1.3 Glow Plug Connectors, Removing and Installing”, page

410

 .

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

and erase all of the DTC entries. Refer to Vehicle Diagnostic

Tester “Guided Functions”.

1.3

Glow Plug Connectors, Removing and

Installing

Special tools and workshop equipment required
♦ Wheel Bolt Cap Pliers - 3314-

410

 

 

 

 

 

 

 

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