Volkswagen Golf / Golf GTI / Golf Variant. Service manual - part 716

4.2

Overview - Intake Manifold Lower Sec‐

tion with Fuel Rail

⇒ “4.2.1 Overview - Intake Manifold Lower Section with Fuel Rail,

Direct Fuel Injection”, page 300

4.2.1

Overview - Intake Manifold Lower Section with Fuel Rail, Direct Fuel Injec‐

tion

1 - Fuel Injector

❑ With combustion cham‐

ber seal (Teflon

®

 seal),

always replace

❑ Replace the O-rings.
❑ Make sure it is installed

in the correct position.

❑ Removing and instal‐

ling. Refer to

⇒ “2.2 Fuel Injectors,

Removing and Instal‐

ling”, page 285

 .

2 - Support Ring

❑ Replace after removing

3 - Fuel Rail for Combustion

Chamber Fuel Injector

❑ 9 Nm
❑ Removing and instal‐

ling. Refer to

⇒ “4.4 Fuel Rail, Re‐

moving and Installing,

Direct Fuel Injection”,

page 309

 .

4 - Roller Tappet
5 - Fuel Pressure Regulator

Valve - N276-
6 - High Pressure Pump

❑ With Fuel Pressure

Regulator Valve - N276-

❑ There is an electric fuel

pump located in the fuel

tank that supplies the

fuel to the mechanical

high pressure pump.

❑ Pay attention when installing the high pressure pump, that no dirt enters the fuel system.
❑ The fuel system must be without pressure to install the high-pressure pump, releasing fuel pressure.

Refer to 

⇒ “1.2 High Fuel Pressure, Reducing”, page 283

 .

❑ Install the fuel lines free of tension
❑ Removing and installing. Refer to 

⇒ “7.2 High Pressure Pump, Removing and Installing”, page 328

 .

7 - High Pressure Pump Bolts

❑ 20 Nm
❑ Replace after removing
❑ Tighten uniformly

8 - High Pressure Line Connection On High Pressure Pump
9 - High Pressure Line Union Nut

❑ 27 Nm

❑ Lubricate the high pressure line with engine oil

10 - High Pressure Line Union Nut

❑ 27 Nm
❑ Lubricate the high pressure line with engine oil

11 - Connections for High Pressure Line On Fuel Rail
12 - Bolts

❑ 9 Nm

13 - Channel Separating Plate
14 - Seal

❑ Check and replace if damaged

15 - Charge-Motion Valve Adjusters (Intake Manifold Flap)
16 - Channel Separating Plate Vacuum Diaphragm (Intake Manifold Flaps)
17 - Intake Manifold Runner Control Valve - N316-
18 - Intake Manifold Sensor - GX9-

❑ 5 Nm
❑ Consists of:

Intake Air Temperature Sensor - G42-

Manifold Absolute Pressure Sensor - G71-

19 - Throttle Valve Control Module - GX3-

❑ Consists of:

EPC Throttle Drive - G186-

EPC Throttle Drive Angle Sensor 1 - G187-

EPC Throttle Drive Angle Sensor 2 - G188-

❑ After replacing or removing and installing, the Throttle Valve Control Module - GX3- must be adapted to

the Engine Control Module - J623- using the Vehicle Diagnostic Tester .

20 - Intake Manifold Stud Bolt

❑ 9 Nm

21 - Intake Manifold Runner Position Sensor - G336-

❑ After replacing or removing and installing, the Intake Manifold Runner Position Sensor - G336- must be

readapted to the Engine Control Module - J623- using the Vehicle Diagnostic Tester .

22 - Intake Manifold

❑ Removing and installing. Refer to 

⇒ “4.3 Intake Manifold, Removing and Installing”, page 304

 .

23 - Fuel Pressure Sensor - G247-

❑ 27 Nm
❑ Coat the sealing point with clean engine oil.
❑ Removing and installing. Refer to

⇒ “5.2  Fuel Pressure Sensor G247 , Removing and Installing”, page 314

 .

4.2.2

Overview - Intake Manifold Lower Sec‐

tion with Fuel Rail, Multiport Fuel Injec‐

tion

Note

Only for vehicles with engine codes CHHB and CXDA

1 - Bolt

❑ 9 Nm
❑ For the intake manifold-

fuel injector fuel rail

2 - Intake Manifold- Fuel Injec‐

tor Fuel Rail
3 - O-Ring

❑ Replace after removing

4 - Fuel Injector

❑ Replace the O-rings.
❑ Make sure it is installed

in the correct position.

❑ Removing and instal‐

ling. Refer to

⇒ “2.3 Intake Manifold-

Fuel Injectors, Remov‐

ing and Installing”, page

287

 .

5 - O-Ring

❑ Replace after removing

6 - Clip
7 - Spring Clamp
8 - High Pressure Pump

❑ With Fuel Pressure

Regulator Valve - N276-

❑ There is an electric fuel

pump located in the fuel

tank that supplies the

fuel to the mechanical

high pressure pump.

❑ Pay attention when in‐

stalling the high pres‐

sure pump, that no dirt enters the fuel system.

❑ The fuel system must be without pressure to install the high-pressure pump, releasing fuel pressure.

Refer to 

⇒ “1.2 High Fuel Pressure, Reducing”, page 283

 .

❑ Install the fuel lines free of tension
❑ Removing and installing. Refer to 

⇒ “7.2 High Pressure Pump, Removing and Installing”, page 328

 .

9 - High Pressure Line Connection

❑ 30 Nm
❑ If the connection was loosened, it must be replaced.

10 - High Pressure Line Union Nut

❑ 27 Nm
❑ High pressure line to the combustion chamber fuel injectors fuel rail

❑ Lubricate the high pressure line with engine oil
❑ Do not install a tensioned high pressure line (pay attention to cleanliness).

11 - Fuel Line Connections

❑ 20 Nm
❑ On vehicles without multiport fuel injection, a sealing plug is installed

12 - Clamp

❑ Replace after removing

13 - Bolt

❑ 5 Nm

14 - Fuel Line

❑ Fuel line to the intake manifold fuel injector fuel rail

15 - Vacuum Diaphragm for Channel Separating Plate
16 - Vacuum Hose
17 - Intake Manifold Runner Control Valve - N316-
18 - Intake Manifold Sensor - GX9-

❑ Consists of:

Intake Air Temperature Sensor - G42-

Manifold Absolute Pressure Sensor - G71-

19 - Bolt

❑ 5 Nm

20 - Intake Manifold

❑ Removing and installing. Refer to 

⇒ “4.3 Intake Manifold, Removing and Installing”, page 304

 .

21 - Intake Manifold Runner Position Sensor - G336-

❑ After replacing or removing and installing, the Intake Manifold Runner Position Sensor - G336- must be

adapted to the Engine Control Module - J623- using the ⇒ Vehicle diagnostic tester.

22 - Intake Manifold Nut

❑ 9 Nm

23 - Intake Manifold Bolts

❑ 9 Nm

24 - Seal

❑ Check and replace if damaged

25 - Low Fuel Pressure Sensor - G410-

❑ 15 Nm
❑ Must be bolted with the adapter -26-
❑ Removing and installing. Refer to

⇒ “5.4  Low Fuel Pressure Sensor G410 , Removing and Installing”, page 318

 .

26 - Adapter

❑ 15 Nm
❑ Must be bolted with the Low Fuel Pressure Sensor - G410-
❑ Replace O-ring

27 - O-Ring

❑ Replace after removing

28 - Clip

❑ For the locating point of the Low Fuel Pressure Sensor - G410- in the fuel rail.