24 - Mixture Preparation - Injection: 1 Safety Precautions and Rules For Cleanliness

CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017
24 – Mixture preparation - injection

1 Safety precautions and rules for
cleanliness
General notes on self-diagnosis ⇒ page 451 .
Safety precautions ⇒ page 272 .
Comply with rules for cleanliness ⇒ page 274 .
1.1 General information on self-diagnosis

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♦ The engine control unit has a self-diagnosis
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♦ Fuel hoses in engine compartment must be secured only with
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♦ For trouble-free operation of electrical components, a voltage
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♦ Do not use sealants containing silicone. Particles of silicone
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drawn into the engine will not be burnt in the engine and dam‐
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t to the co
age the Lambda probe.
♦ Vehicles are fitted with a crash fuel shut-off circuit. It reduces
the danger of a fire in a crash as the fuel pump is switched off
rrectness of i
via the fuel pump relay.
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♦ The system also improves the starting characteristics of the

engine. When the driver door is opened, the fuel pump is ac‐ nform
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tivated for 2 seconds in order to build up pressure in the fuel

system, observe safety precautions ⇒ page 272 .
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1. Safety precautions and rules for cleanliness 451

2 Injection system
Technical data ⇒ page 452 .
Fitting locations - overview ⇒ page 452 .
Assembly overview - air filter ⇒ page 458 .
Removing and installing air filter housing ⇒ page 459 .
Removing and installing air filter element ⇒ page 460 .
Removing and installing air mass meter - G70- ⇒ page 461 .
Assembly overview - intake manifold ⇒ page 461 .
Assembly overview - fuel rail ⇒ page 464 .
Removing and installing intake manifold with fuel rail
⇒ page 465 .
Removing and installing injectors ⇒ page 472 .
Renew Teflon seal on injector ⇒ page 475 .
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Clean injectors ⇒ page 477 . ksw
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Removing and installing fuel pressure
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sender - G247- ara
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⇒ page 478 . ut
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Removing and installing throttle valve module - J338- s
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⇒ page 479 .
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Cleaning throttle valve module - J338- ⇒ page 480 .
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Assembly overview - high-pressure pump with fuel pressure reg‐

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ulating valve - N276- ⇒ page 481 .

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Removing and installing high-pressure pump ⇒ page 483 . spec

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2.1 Technical data

Engine code BZB, CAWA, CAWB, CBFA, CCTA, CCTB, CGYA,
rrectne
CCZA, CCZB, CCZC, CCZD, CDAA, CDAB

Idling check
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Idling speed 1) rpm 640 to 800

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Governed speed rpm approx. 6500

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If voltage supply to engine control unit drops below 12 volt,

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idling speed will be raised incrementally up to 990 rpm. The idling

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speed cannot be adjusted.

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2.2 Overview of fitting locations
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452 Rep. gr.24 - Mixture preparation - injection

1 - Inlet camshaft control valve

1 - N205-
❑ Removing and installing
⇒ page 90
2 - Charge pressure control
solenoid valve - N75-
❑ Installed directly on tur‐
bocharger ⇒ page 457
3 - Turbocharger air recircula‐
tion valve - N249-
❑ Installed directly on tur‐
bocharger ⇒ page 457
4 - Ignition coils with output
stages
⇒ page 553
❑ Ignition coil 1 with output
stage - N70-
stage - N127-
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stage - N291-
stage - N292-
❑ Puller - T40039- is re‐
quired for removing igni‐
tion coils from cylinder
head.
5 - Engine (motor) control unit AG. Volkswagen AG d
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- J623- Volksw
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❑ Removing and installing rised
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- Passat, CC ut
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⇒ page 490 . ss a c
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- Golf, Eos ⇒ page 493

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❑ Removing and installing - Tiguan ⇒ page 502

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❑ Removing and installing - Scirocco ⇒ page 505

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6 - High-pressure pump with fuel pressure regulating valve - N276-

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❑ Fitting location:
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Engine codes BZB, CAWA, CAWB, CBFA, CCTA, CCTB, CGYA, CDAA, CDAB ⇒ page 455 .
Engine codes CCZA, CCZB, CCZC, CCZD ⇒ page 455

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❑ Removing and installing ⇒ page 483

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❑ Assembly overview - high pressure pump ⇒ page 481 .

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7 - Fuel pressure regulating valve - N276-

❑ Fitting location:
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Engine codes BZB, CAWA, CAWB, CBFA, CCTA, CCTB, CGYA, CDAA, CDAB ⇒ page 455 .
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Engine codes CCZA, CCZB, CCZC, CCZD ⇒ page 455

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2. Injection system 453

8 - Radiator outlet coolant temperature sender - G83-

❑ Passat, CC, Golf, Eos, Scirocco: In lower union on radiator ⇒ page 264 .
❑ Tiguan: in coolant hose ⇒ page 266
9 - Vacuum unit for air flow control flaps
❑ Fitting location ⇒ page 456
10 - Intake manifold flap air flow control valve - N316-
11 - Engine speed sender - G28-
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❑ Location: Bottom left at front ⇒ page 456 agen oes
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12 - Charge air pressure sender - G31- rised
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❑ Fitting location ⇒ page 457 s aut ra
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13 - Electrical connector for knock sensor 1 - G61-
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❑ Location: Below intake manifold ⇒ page 457
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❑ Knock sensor 1 - G61- specified torque: 20 Nm
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14 - Electrical connector for Hall sender - G40-
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15 - 8-pin connector for injectors
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16 - Throttle valve module - J338-
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❑ Including throttle valve drive (electric throttle operation) - G186- , angle sender 1 for throttle valve drive
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(electric throttle operation) - G187- and angle sender 2 for throttle valve drive (electric throttle operation)
- G188- .
❑ After renewing throttle valve module - J338- it must be reprogrammed to engine control unit - J623-
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⇒ Vehicle diagnostic tester

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17 - Activated charcoal filter solenoid valve 1 - N80-
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❑ One unit with non-return valve/throttle
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❑ To remove and install, remove intake manifold

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18 - Intake air temperature sender - G42-
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❑ Bolted to front intake manifold ⇒ page 461 C py
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19 - Knock sensor 1 - G61- copy Vo
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❑ Location: Below intake manifold Prote AG.
❑ Specified torque: 20 Nm
20 - Radiator outlet coolant - G62-
❑ In coolant pump housing ⇒ page 457
21 - Hall sender - G40-
❑ Bolted to front of cylinder head cover ⇒ page 456
22 - Fuel pressure sender - G247-
❑ On fuel rail ⇒ page 464
23 - Intake manifold flap potentiometer - G336-
❑ On intake manifold on right
❑ To remove and install, remove intake manifold ⇒ page 465 .
24 - Oil pressure switch - F1-
❑ In bracket for ancillary units
Engine codes CAWA, CAWB, CBFA, CCTA, CCTB, BZB, CGYA ⇒ page 219 .
Engine codes CCZA, CCZB, CCZC, CCZD, CDAA, CDAB ⇒ page 223

A - Diagnosis connector
❑ In footwell on driver side
B - Air mass meter - G70- and intake air temperature sender 2 - G299-
C - Accelerator position sender - G79- and accelerator position sender 2 - G185-
❑ On accelerator (both senders are accommodated in one housing)
❑ If accelerator module or engine control unit is renewed, kick-down function must be taught-in on vehicles
with automatic gearbox.
❑ Removing and installing ⇒ page 382 gen AG. Volkswagen AG
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D - Radiator fan control unit - J293- d by Vo ot g
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❑ The radiator fan control unit or-is J293- is integrated into the radiator fan -ntV7-
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E - Injectors ss c
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❑ In fuel rail
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❑ Injector, cylinder 1 - N30-
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High-pressure pump, engine codes BZB, CAWA, CAWB, CBFA,
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CCTA, CCTB, CGYA, CDAA, CDAB
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2 - High-pressure pump
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High pressure pump engine codes CCZA, CCZB, CCZC, CCZD
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4-cyl. injection engine (1.8 and 2.0 wl gen AG chain drive)
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Intake manifold flap valve - N316- rise
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1 - Vacuum unit for air flow control
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Air mass meter - G70- and intake air temperature sender 2 -
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G299- -1-
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Engine speed sender - G28- -1-
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Hall sender - G40- -1-

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1 - From Hall sender - G40- ise
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2 - From knock sensor 1 - G61- s aut ra
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3 - 8-pin connector for injectors
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Coolant temperature sender - G62- -1-
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Below intake manifold (intake manifold is removed in illustration)
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Charge air pressure sender - G31- -1-
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Components on turbocharger
1 - Removing and installing turbocharger ⇒ page 424
2 - Tighten charge pressure control solenoid valve - N75- to 3 Nm
3 - Tighten turbocharger air recirculation valve - N249- to 7 Nm
(note installation position, refer to next illustration)

Pay attention to installation position of turbocharger air recircula‐

tion valve - N249-
2.3 Assembly overview - air filter
1 - Spring-type clip
2 - Air intake hose
❑ To turbocharger
❑ Check air hose for con‐
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tamination and leaves
3 - Air mass meter - G70-
⇒ page 461
4 - Bolts
❑ 1.5 Nm
❑ For upper part of air fil‐
ter.
5 - Bolts
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❑ For upper part of air fil‐ rised b ara
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6 - Air filter upper part s
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❑ Clean any salt residue,

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per part of air filter

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7 - Filter element
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❑ Always use genuine

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part for air filter element

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⇒ page 460
❑ Observe change inter‐
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vals ⇒ Maintenance ;
Booklet ; Service tables
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8 - Bolt
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❑ 8 Nm
❑ For air filter lower part
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9 - Snow screen
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❑ Not fitted in all vehicles.

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10 - Air filter lower part

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❑ Clean any salt residue, leaves and dirt from lower part of air filter.
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11 - Connection for water drain hose rig ht
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❑ Clean connection
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12 - Water drain hose

❑ Clean water drain hose
13 - Flutter valve
14 - Intake air guide
❑ To lock carrier.
❑ Clean any leaves and dirt out of intake air duct
2.4 Removing and installing air filter hous‐

ing
Removing:
Proceed as follows:
– Pull cover off air duct (release clips on sides) -arrows-.
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– Release clips -arrows- air duct at the bottom and remove duct.
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– Detach air duct at bottom together with air hose.
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Engine code CBFA:
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– Pull hose to secondary air pump motor - V101- from air filter
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– Pull off connector -1- from air mass meter - G70- .

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– Remove hose clips -2- and -3- and remove connecting pipe.
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– Remove bolt -4- and pull air filter housing upwards out of
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Installing:
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Install in reverse order of removal.

2.5 Removing and installing air filter ele‐

ment
Removing
Engine code CBFA:
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– Pull hose to secondary air pump motor - V101- from air filter yV
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– Remove bolts -arrows- from upper part of air filter.
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– Lift up upper part of air filter and remove air filter element.
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Specified torques: ⇒ page 458 is n
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Note
♦ Always use genuine part for air filter element.
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♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly. Do not use lubricants
ss
containing silicone.
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♦ The air filter housing must be clean.
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♦ Secure all hose connections with the correct type of hose clips
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(same as original equipment): ⇒ ETKA (Electronic parts cata‐
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♦ To prevent malfunctions, cover all critical engine air ducting
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components such as air mass meter, intake pipes, etc. with a
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clean cloth when blowing out the air filter housing with com‐
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♦ Please observe disposal instructions!
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– Check air mass meter and intake hose for salt residue, dirt and
leaves (engine intake side).
– Check for dirt in air intake hose from air duct.
– Remove snow screen -1- and clean it.
Note
The snow screen is not installed in all vehicles.

– Clean water drain -arrow- and lower part of air filter.

– When installing the air filter element, check that it is properly
centred in the retainer in lower part of air filter.
– Place upper part of air filter carefully on lower part of air filter
without exerting excessive force. Make sure the upper part of
the air filter is fitted straight on the air filter element (note po‐
sition of sealing lip on air filter element).
Continue installation in reverse order of removal.
2.6 Removing and installing air mass meter

- G70-
– Separate electrical connector -1- on air mass meter - G70- .
– Unscrew both bolts from air mass meter - G70- and carefully
pull air mass meter - G70- out of guide on air filter housing.
Installing
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To ensure proper operationwage
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♦ If the air filter element is very dirty or wet, dirt or water could
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reach the air mass meter - G70- and affect the air mass value.
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quantity is calculated.
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♦ Always use genuine part for air filter element.

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♦ Use a silicone-free lubricant when installing the intake hose.

♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ EKTA (Electronic parts cata‐
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logue) .
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– Check air mass meter and intake hose for salt residue, dirt and
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leaves (engine intake side).

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– Check for contamination of intake duct as far as air filter ele‐

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ment. If contamination is found, remove salt residues, dirt and

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leaves from top and bottom part of air filter housing by rinsing
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out or using a vacuum cleaner if necessary. Removing and

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installing air filter ⇒ page 460

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2.7 Assembly overview - intake manifold
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1 - Screw for intake air temper‐

ature sender - G42-
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2 - Intake air temperature
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sender - G42- utho eo
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3 - Activated charcoal filter sol‐
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enoid valve 1 - N80-
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❑ One unit with non-return
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❑ To remove and install,
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remove intake manifold
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4 - Intake manifold
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⇒ page 465
❑ Specified torque of bolts
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⇒ Item 15 (page 465)
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5 - Vacuum unit for air flow

control flaps
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6 - Bolts for high-pressure
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❑ M6 thread = 8 Nm + 90°
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❑ M8 thread = 20 Nm.
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7 - Connecting piece for fuel
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supply line from fuel tank
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8 - Fuel pressure regulating cop Vo
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valve - N276-
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❑ With fuel pressure regu‐
lating valve - N276- .
❑ When installing the
high-pressure pump,
ensure that no dirt enters the fuel system
❑ The fuel system must not be under pressure when installing the high-pressure pump; procedure for
reducing fuel pressure ⇒ page 272
❑ Install fuel line to fuel rail without tension
10 - Roller tappet
❑ May remain inserted in vacuum pump after removal of high-pressure pump, removable
11 - Union for high-pressure fuel line
❑ Torque setting ⇒ page 481 .
12 - Fuel pipe to fuel rail
❑ Fuel line must be installed free of tension
❑ Torque setting ⇒ page 481 .
13 - Intake manifold flap air flow control valve - N316-
14 - Injectors
❑ Renew O-rings
❑ Ensure correct installation position
15 - Non-return valve/throttle
❑ Different versions, allocation ⇒ ETKA (Electronic parts catalogue)

❑ One unit with activated charcoal filter system solenoid valve 1 - N80-
16 - Intake manifold support
17 - Bolt for intake manifold support
❑ 23 Nm
18 - Securing nut for intake manifold support
❑ 10 Nm
19 - Bolts for throttle valve module - J338-
❑ Qty. 4
❑ 5 Nm
20 - Throttle valve module - J338- , throttle valve drive for electric throttle operation - G186-
❑ Throttle valve drive angle sender 1 for electric throttle - G187- and throttle valve drive angle sender 2 for
electric throttle - G188-
⇒ Vehicle diagnostic tester via “Guided Functions”
❑ Cleaning ⇒ page 480
21 - Sealing ring
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❑ Renew
❑ Lug of seal must lie in intended groove in intake manifold.
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2.8 Assembly overview - fuel rail
1 - Injection valve
❑ With combustion cham‐
ber ring seal (Teflon ring
seal): always renew
❑ Renew O-rings
❑ Ensure correct installa‐
tion position
⇒ page 472
2 - Support ring
3 - Fuel rail
⇒ page 472
❑ With fuel pressure regu‐
lating valve - N276- .
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❑ An electric fuel pump
(fitted in fuel tank) sup‐
plies fuel to the mechan‐
ical high-pressure pump
at a pressure of approx.
6 bar.
❑ When installing the
high-pressure pump,
ensure that no dirt en‐
ters the fuel system
❑ The fuel system must
not be under pressure
when installing the high-
pressure pump; proce‐ AG. Volkswagen AG d
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pressure ⇒rispage 272
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⇒ page 483
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5 - Roller tappet
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7 - Bolts for high-pressure pump

❑ Renew
❑ M6 thread = 8 Nm + 90°
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8 - Connection for fuel supply line

❑ Counter-hold connection when loosening union nut.
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❑ If the union nut or the connection is detached, the connection must be renewed.
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10 - Air flow control flaps

11 - Seal
❑ Renew
12 - Intake manifold
13 - Vacuum unit for air flow control flaps
❑ Checking ⇒ page 487
14 - Throttle valve module - J338- , throttle valve drive for electric throttle operation - G186-
❑ Throttle valve drive angle sender 1 for electric throttle - G187- and throttle valve drive angle sender 2 for
electric throttle - G188-
⇒ Vehicle diagnostic tester via
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❑ Checking ⇒ page 485
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Other specified torques
Further specified torques can be found at end of chapter entitled ss
“Disconnecting fuel rail from intake manifold” ⇒ page 472 .
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2.9 Removing and installing intake manifold

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Special tools and workshop

equipment required
♦ Hexagon bit, long reach -
T10347-
♦ Oil filter tool - 3417-
♦ Torque wrench - V.A.G
1331-
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♦ Observe all relevant safety precautions ⇒ page 272 .

♦ Observe rules for cleanliness ⇒ page 274 .
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♦ The injectors can only be accessed after removal of the intake

manifold and fuel rail with air flow control flap.
ss o
♦ Combustion chamber ring seal (Teflon) and O-ring must al‐

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ways be renewed.
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♦ Assembly overview - intake manifold ⇒ page 461 .

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♦ Assembly overview - fuel rail ⇒ page 464

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Removing
– Only vehicles with sound generator: Remove charge air duct
to sound generator ⇒ page 447 .
– Remove engine cover panel ⇒ page 139 .
– Clean joint between intake manifold and cylinder head.
– Remove air filter housing ⇒ page 459 .
Golf, Eos, Scirocco:
– Remove radiator cowl ⇒ page 267 .
All:
– Disconnect vacuum line -arrow- to activated charcoal filter.

– Disconnect the following electrical connectors:
♦ Intake air temperature sender - G42- -1-
♦ Throttle valve module - J338- -2-
♦ Activated charcoal filter solenoid valve 1 - N80- n AG. Volkswagen AG
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– Unscrew bolts -arrows- for fuel supply pipe and lay pipe to
at
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side.
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WARNING
The fuel system is pressurised.

Danger of injury through fuel spray.
♦ Wear safety goggles.
♦ Wear protective gloves.
♦ To release pressure, wrap a clean cloth around the con‐
nection and carefully loosen the connection.
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– Unscrew fuel pipe union nut -lower arrow-. orise nte
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– Unscrew coolant line bolts -arrows- from intake manifold.
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– Pull electrical connector -1- from fuel pressure sender -

G247- .

– Release hose clip -2-.

– Unscrew bolt -4-. AG. Volkswagen AG d
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– Separate electrical
by V connector -arrow-.
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– Removeuthnoise
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insulation ⇒ General body repairs, exterior; eo
Rep. sgr.
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– Remove charge air hose -A- and seal charge air cooler with a
t to the co
clean cloth.
rrectness of i
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– Unbolt bracket from intake manifold -arrows-.

– Remove throttle valve module - J338- -arrows-.
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– Remove intake manifold support; to do this, unscrew securing ss c
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– Remove oil filter ⇒ page 219 .
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– Detach cable retainer -arrows-.
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– Detach cables -arrows- from intake manifold.

– Unscrew nuts -A- and remove bolts -arrows- for intake mani‐
fold using socket Torx T30 - T10347- .
– Carefully pull intake manifold with fuel rail slightly away from
cylinder head.
– Disconnect electrical connector -arrow- from intake manifold

flap potentiometer - G336- and remove intake manifold.
– Seal intake ports with a clean cloth.
Note
The injectors can remain in the fuel rail.
cardiagn.com
– Disconnect fuel rail from intake manifold ⇒ page 472 .
Installing:
• Injectors must be installed in cylinder head. Installing injectors
⇒ page 472
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– Fit intake manifold onto
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again insert the injectors into the cylinder head.

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Further assembly is performed in the reverse order of removal.

During this step, observe the following:
rrectness of i
– On engaging cable retainer onto intake manifold, also clip in

the other two retainers.
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Specified torques: refer to assembly overview of intake manifold

⇒ page 461 .
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Specified torques: refer to assembly overview of fuel rail

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⇒ page 464 .
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2.9.1 Disconnecting fuel rail from intake mani‐

fold
Note
Intake manifold must be removed; removing intake manifold

⇒ page 465 .
– Pull activated charcoal filter system solenoid valve 1 - N80-

-arrow- from retainer.
– Loosen non-return valve -1- and fuel line -2-.
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Installing
– Tighten fuel line.
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– Continue installation in reverse order of removal.
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– Re-connect electrical connectors.

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– Install intake manifold ⇒ page 465 .

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Torque settings
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Adapter for fuel line to fuel rail (renew) 40 Nm

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Fuel line (union nut) to adapter for fuel rail 27 Nm

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2.10 Removing and installing injectors
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Special tools and workshop equipment required
♦ Tool set - T10133-

Note
Puller - T10133/2- has been modified and is now designated pull‐

er - T10133/2A- . If the new tool is not yet available in the
workshop, perform the modification yourself.
Convert puller - T10133/2- tool to puller - T10133/2A- tool.

♦ Round file approx. 6 mm
– File out a semi-circular recess as shown in the illustration. The
recess allows the tool to be pushed further onto the injector so
the contact surface is increased.
– For identification purposes, mark the modified tool with the
letter “A” after the tool number.
cardiagn.com
Injector (old version)
1 - Combustion chamber ring seal (Teflon ring seal), renew; when
fitting, do not grease ring or use any other lubricant.
2 - The support ring must be replaced with an intermediate ring.
See Injector (new version)
3 - Injection valve AG. Volkswagen AG d
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4 - Injection valve
5 - Spacer (renew if damaged)
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6 - O-ring (renew; to install, lightly lubricate with clean engine oil).
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7 - Support ring (via this support ring, fuel rail exerts force which
secures injector in cylinder head)
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Removing:
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– Remove intake manifold with fuel rail ⇒ page 465 .
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– Seal intake ports with a clean cloth.
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– Remove supporting element -A- and pull off connectors

-arrows- from injectors.
– Apply puller -T10133/2A- to groove on injector.

– Position removal tool -T10133/16- and pull injector out by turn‐
ing bolt -1-.
Note
♦ Note the intermediate rings.

♦ The Teflon seal must always be renewed prior to reinstallation
of the injector ⇒ page 475 .
Installing:
Note
♦ The Teflon seal on the injector must not be oiled or greased.

♦ It is possible that an open inlet valve hinders cleaning. In this
case, turn engine by hand at crankshaft using a spanner.

– Thoroughly clean holes of high-pressure injectors in cylinder

head using a nylon brush - T10133/4- .
– Renew Teflon seal of injector ⇒ page 475 .
– Complete injector with parts from the repair set.
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– Push injector by hand as far as it will gouinto
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positioned correctly -arrow- in cylinder head.
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– Fit support ring onto injector.
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– Lightly moisten O-rings of the high-pressure injector with clean
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2.11 Renewing Teflon seal on injector
♦ Tool set - T10133-
Note
The Teflon ring must not be lubricated.

– Carefully remove old Teflon ring using suitable tools (e.g. cut
open ring using razor blade, or prise open ring with small gen AG
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– Carefully clean injector in area of seal -arrow-.
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– Fit new seal onto assembly cone - T10133/5- . Push seal as

far as possible onto assembly cone - T10133/6- using assem‐
nform
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bly sleeve - T10133/5- .

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– Turn assembly sleeve - T10133/6- around and push seal to

end of assembly cone - T10133/5- .
– Fit assembly cone - T10133/5- on injector and push seal onto

injector using assembly sleeve - T10133/6- .
– Remove assembly cone - T10133/5- and push seal into
groove using assembly sleeve - T10133/6- .

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– Push calibration sleeve - T10133/7- onto injector as far as it
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– Now press calibration sleeve - T10133/8- onto injector to stop
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by turning gently (approx. 180°).

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– Pull calibration sleeve - T10133/8- off again by turning it in the
on in
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– Renew O-ring and support washer on injector.
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2.12 Cleaning injectors

♦ Ultrasonic cleaning device - VAS 6418-
♦ Mounting plate for injection modules - VAS 6418/1-
♦ Cleaning fluid - VAS 6418/2-
Cleaning
– Remove injectors ⇒ page 472 .
Note
Comply with safety regulations and instructions for ultrasonic unit.
– The ultrasonic unit must be filled with cleaning fluid - VAS

6418/2- .
Note
The ultrasonic unit must be filled with cleaning agent to upper

edge of holes (see detail).
– Insert injectors -1- into mounting plate for injection modules -

VAS 6418/1- as far as stop -2-.

– Dip injectors together with mounting plate for injection mod‐

ules - VAS 6418/1- into cleaning fluid.
– Set a temperature of 50 degrees with the rotary knob -4-.
– Set the rotary knob -5- to a cleaning time of 30 minutes.
– Switch the ultrasonic unit on with button -3-.
Note
As soon as the cleaning temperature is 50 degrees, the set time

will begin to elapse. n AG. Volkswagen AG do
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– After cleaning, always replace combustion chamber ringir se seal
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(Teflon seal) for each injector ⇒ page 475 . utho
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– Then reinstall injectors ⇒ page 472 .
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2.13 Removing and installing fuel pressure
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♦ Assembly tool - T10118-
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Removing:
Vehicles with sound generator:
– Remove charge air duct to sound generator ⇒ page 447 .

CC 2010 agen➤ , Eos 2006 ➤
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oes
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– Remove retainer from top of alternator - C- -arrow-.
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– Detach coolant pipe from intake manifold -arrows-.
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– Release connector from fuel pressure sender - G247- using

assembly tool - T10118- .
WARNING

– Unscrew fuel pressure sender - G247- using deep hexagon

socket, 27 mm - VAS 5301/7- .
– Collect escaping fuel with a cleaning cloth.
Installing:
Install in reverse order of removal, observing the following.
Lubricate sealing cone of fuel pressure sender - G247- with clean
engine oil.
– Specified torques ⇒ page 464 .
2.14 Removing and installing throttle valve

module - J338-
Removing:
– Remove charge air duct to sound generator ⇒ page 447 .


– Remove radiator cowl ⇒ page 267 .
All:
– Release hose clip -2-.
– Unscrew bolt -4-.
– Separate electrical connector -arrow-.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Noise insulation .
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– Remove bolt -1- and take out air pipe downwards.
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– Separate electrical connector -1- on throttle valve module -

J338- .
– Remove bolts -arrows- and detach throttle valve module -
J338- .
Installing:
Install in reverse order of removal, observing the following.
Specified torques ⇒ page 461 .
– Clean sealing surface for O-ring.
– Renew gasket, making sure that service lug is correctly posi‐
tioned on oil seal.
– If a new throttle valve module - J338- was installed, adapt the
engine control unit to throttle valve module - J338- ⇒ Vehicle
diagnostic tester “Guided Functions”.
2.15 Cleaning throttle valve module - J338-


♦ Acetone
Note
♦ Observe rules for cleanliness ⇒ page 274 .

♦ When cleaning the throttle valve housing it must not be
scratched.
Procedure:
– Remove throttle valve module ⇒ page 479 .
– Open throttle valve by hand and block throttle valve in open
position with a suitable object -arrow-.
WARNING
Acetone is highly inflammable. Please comply with the acci‐

dent prevention regulations and the safety instructions when
handling highly inflammable fluids. Do not use compressed air
when cleaning the throttle valve. Wear protective goggles and
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protective clothing to avoid injury and contact with the skin.
– Thoroughly clean throttle

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2.16 Assembly overview - high-pressure

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- N276-
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1 - O-ring
❑ Renew
2 - Roller tappet
❑ May remain inserted in
vacuum pump after re‐
moval of high-pressure
pump, removable
3 - Fuel high pressure pipe
connecting piece (with inner
thread)
❑ 25 Nm
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❑ M6 thread = 8 Nm + 90°
❑ With fuel pressure regulating valve - N276- .
❑ When installing the high-pressure pump, ensure that no dirt enters the fuel system
❑ Install fuel line to fuel rail without tension

2.17 Removing and installing high-pressure

pump
Note
♦ The high-pressure pump should be removed and installed only

when the engine is cold.
♦ When installing the high-pressure pump, it is essential to en‐
sure that no dirt enters the fuel system.
♦ Catch escaping fuel with a cleaning cloth.
♦ The O-ring and the union must always be renewed.
♦ Always ensure that high-pressure fuel lines are free of stress
when installed.
Removing
– Remove air filter housing ⇒ page 459 .
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– Pull off electrical connector -2- from fuel pressure regulating
valve - N276- .
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– Open both fuel pipes -arrows-.

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– Unscrew 2 bolts -arrows-. d by V ua
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autho
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ac
cumstances, the roller tappetss may become stuck in the cylin‐
der head.
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♦ The connection for fuel supply line (high-pressure side) must
be renewed. See assembly overview for high pressure pump
rrectne
⇒ page 481 .
ss
♦ Specified torques ⇒ page 481
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– Tighten union nut on fuel supply pipe hand-tight, »align stress-

free« and then tighten.
– Re-connect electrical connector -2- for fuel pressure regulat‐

ing valve - N276- .
– Put back fuse if it has been removed.
– Install air filter housing ⇒ page 459 .
– Start engine and check fuel system for leaks.
– Fit engine cover panel ⇒ page 139 .

3 Checking components
Checking fuel pressure sender - G247- ⇒ page 485 .
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VAS 6394/1-
♦ Adapter - VAS 6394/2-
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♦ Adapter - VAS 6394/4- (on‐
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♦ Test adapter - VAS 5570-
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3. Checking components 485

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– Seal charge air duct connection to sound generator with plug
itte
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Note
For the Tiguan, use adapter - VAS 6394/4- instead of adapter -
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VAS 6394/2- .
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– Moisten tapered seal of adapter - VAS 6394/2- with clean en‐

gine oil and screw into fuel rail. Specified torque: 27 Nm.
nform
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or
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– Unscrew plug -2- and screw fuel pressure sender - G247- into
tester - VAS 6394/1- . Specified torque: 27 Nm.
– Connect pressure line of tester - VAS 6394/1- to adapter - VAS
6394/2- .
– Connect fuel pressure sender and electrical connector of fuel

pressure sender with the aid of test adapter - VAS 5570- .

– Switch on tester - VAS 6394/1- to do this, press button -A- once

briefly.
Note
♦ When button -A- is pressed for 2 seconds, the illumination will

be switched on for 20 seconds.
♦ If the digital pressure gauge - VAS 6394/1- reading is not 0
bar, perform zero calibration procedure ⇒ operating instruc‐
tions .
– Connect vehicle diagnostic tester to diagnostic connection.

– Switch ignition on.
– Press following buttons on display of diagnostic tester one af‐
ter the other:
Vehicle self-diagnosis
Self-diagnosis ►
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01 - Engine electronics ►
011 - Measured values ►
– Select measured value block 1 4 0 and confirm with Q .

The actual fuel pressure value is shown in display zone 3, meas‐
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3.2 Checking intake manifold change-over
AG.
Perform check only if there is a loss of torque. This means when

there is a lack of elasticity or a lack of pulling power.

♦ Hand operated vacuum pump - VAS 6213-
Prerequisites for check

♦ The variable intake manifold valve - N316- was checked with
a vehicle diagnostic tester .
If the intake manifold flap valve - N316- is OK, perform the fol‐
lowing tests:
– Pull engine cover panel off carefully.
cardiagn.com
– Start engine and run it at idling speed.
– Have second person abruptly increase engine speed (throttle
burst). Observe vacuum unit for intake manifold change-over.
• The actuator must move -arrow-
If changeover does not operate as indicated:
– Check vacuum system for leaks.
– Check mechanical change-over components for ease of
movement. To do this, operate rods by hand.
– Check that vacuum lines are connected correctly.
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– Check vacuum hoses for
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– Move slide ring -1- on hand vacuum pump - VAS 6213- to po‐
sition -A- for “vacuum”.
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– Connect hand vacuum pump - VAS 6213- to actuator
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– Operate hand vacuum pump - VAS 6213- repeatedly.
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4 Engine control unit - J623-s (Passat, au
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Removing and installing engine control unit ⇒ page 490 .
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Removing and installing engine control unit with protective hous‐
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4.1 Removing and installing engine control
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Note
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ing ⇒ page 491 .
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mer
– If you wish to renew the engine control unit, connect the vehi‐
atio
m
cle diagnostic tester and perform the guided function “Renew‐

o
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c
ing engine control unit”.
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Removing engine control unit
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– Switch off ignition.
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– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐ C py
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– Remove right plenum chamber cover ⇒ General body repairs, Prote
cted AG.
agen
exterior; Rep. gr. 64 ; Flush-bonded windows; Assembly over‐
view - plenum chamber cover .
– Pull connector -1- off heated windscreen control unit - J505- .
– Slide connector locking devices -2- on engine control unit out‐
wards and pull off both connectors.
– Remove securing bolts -3-.
– Remove retainer frame with engine control unit from plenum
chamber.
– Press locking device -1- outwards and slide engine control unit
-2- out in -direction of arrow-.
Installing engine control unit

– Slide engine control unit -1- into retaining frame in

-direction of arrow-.
– Fit retainer frame with engine control unit onto retainer -4-.
Specified torque of securing nuts for retainer -4-: 6 Nm.
– Tighten securing bolts -3- to 7 Nm.
– Fit connectors to engine control unit and slide locking devices
-2- inwards.
– Fit connector -1- to heated windscreen control unit - J505- .
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– Install right plenum chamber cover
AG. Vol⇒
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screen wiper
ss system; Removing and installing wiper arms. c
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– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐

screen wiper system; Removing and installing wiper arms .
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terior; Rep. gr. 64 ; Flush-bonded windows; Assembly over‐

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– Raise engine control unit with retaining frame slightly.
– Release engine control unit -arrows- and pull out slightly.
4. Engine control unit J623 (Passat, CC up to 11/10) 491

– Bend the upper ends -1- of locking clip outwards.

– Remove shear-head bolts -2- using grip pliers and remove
locking clip.

– Remove engine control unit.
Installing:
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– Slide engine control unit -1- in direction of -arrow- in retaining
ab
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– Take a new locking clip and tighten new shear-head bolts

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by
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screen wiper system; Removing and installing wiper arms.
AG.

5 Engine control unit - J623- (Golf, Eos

to 11/08)
ing ⇒ page 493 .

unit
Note
If you wish to renew the engine control unit, connect the vehicle
diagnostic tester and perform the guided function “Renewing en‐
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– Switch
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– Remove windscreen wiper arms, plenum chamber cover and an
d
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– Lever up catch -2- slightly.

– Then push engine control unit out of retainer -arrow-.
rrectne
– Then release rear connector on engine control unit and pull it

off.
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– Fit rear connector to engine control unit and lock in position.

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– Push engine control unit onto bracket.

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– Fit front connector to engine control unit and lock it in position.

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– Install plenum chamber bulkhead, plenum chamber cover and

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♦ Electric cutter - V.A.G 1561 A-
♦ Saw set - V.A.G 1561/14-
5. Engine control unit J623 (Golf, Eos to 11/08) 493

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♦ Hot air blower from wiring harness repair set - VAS 1978 B-
o
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Note
gine control unit”.
Removing:
– Remove windscreen wiper arms, plenum chamber cover and
plenum chamber bulkhead ⇒ Electrical system; Rep. gr. 92 ;
Windscreen wiper system; Removing and installing wiper
arms .
Note
The shear-head bolt threads are coated with locking compound.

Heating the shear-head bolt with a hot air blower releases the
locking effect of the locking compound.
Caution
Cover lines, connections and control units in the vicinity of the

engine control unit to prevent damage through heat.
Perform settings on hot air blower -4- as shown:

– Turn temperature setting potentiometer -2- to maximum heat

output (600°C).
– Set two-stage switch for volume of air -3- to position 3.
WARNING
When shear-head bolts are heated up, parts of the protective

housing will be subjected to a large amount of heat. Wear pro‐
tective gloves to avoid possible injury.
– Place nozzle of hot air blower close to shear-head bolt.

– Switch on hot air blower and heat the bolts.
– Remove bolts with grip pliers .
Note
If the bolts will not move, saw into heads of shear-head bolts so
that two parallel slots are created -arrows- and then remove the
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bolts.
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– Insert a screwdriver betweenauprotective
th housing -A- and ra
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– Lever up protective housing using screwdriver -A- and pull to

side off bracket -arrow-.
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5. Engine control unit J623 (Golf, Eos to 11/08) 495

– Release front connector -1- from engine controlwunit

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– Then release rear connector on engine control unit and pull it
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Installing:
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– Fit front connector to engine control unit and lock it in position.
– Push protective housing onto bracket.
rrectness of i
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6. Engine control unit J623 (Golf, Eos, Scirocco from 11/08; CC from 11/10) 497

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– Insert engine control unit into retaining frame andopress re‐

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bulkhead .
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All:
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6. Engine control unit J623 (Golf, Eos, Scirocco from 11/08; CC from 11/10) 499

connectors off.
Installing

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– Insert engine control unit into retaining frame and press re‐
– Install wiper arms, plenum chamber cover and plenum cham‐
ber bulkhead ⇒ Body; Rep. gr. 50 ; Plenum chamber bulk‐
head .
Passat, CC:
– Install wiper arms and plenum chamber cover ⇒ Body; Rep.
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7 Engine control unit - J623- (Tiguan)

ing ⇒ page 503 .

unit
diagnostic tester and perform the guided function “Renewing con‐
trol unit”.
Removing
– Remove wiper arms ⇒ Electrical system; Rep. ogr.
lksw92 ; Wind‐
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screen wiper system; Removing and installing
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terior; Rep. gr. 64 ; Removing and installing
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on in
-2- in -direction of arrow-.

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erm
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en
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trol unit”.
♦ Grip pliers
Removing
– Remove wiper arms, ⇒ Electrical system; Rep. gr. 92 ; Wind‐
– Remove plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr. 64 ; Removing and installing plenum chamber
cover.
– Unscrew bolts -1-.
– Cover the plenum chamber with a clean cloth so that it is not
scratched.
– Raise engine control unit with retaining frame slightly.
– Release engine control unit in direction of -arrow- and pull out
slightly.
7. Engine control unit J623 (Tiguan) 503

– Bend the upper ends -1- of locking clip outwards.

– Remove shear-head bolts -2- using grip pliers and remove
locking clip.

– Remove engine control unit.
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hole
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spec
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Specified torque: 6 Nm
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connectors off.
Installing

8. Engine control unit J623 (Scirocco to 11/08) 505

– Install plenum chamber bulkhead ⇒ General body repairs;
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locking clips.


connectors off.
Installing

cardiagn.com
– Fit the two locking clips over the connector and secure with
new shear-head bolts -arrows-.
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-arrows-.
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8. Engine control unit J623 (Scirocco to 11/08) 507

24 - Mixture Preparation - Injection: 1 Safety Precautions and Rules For Cleanliness

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24 - Mixture Preparation - Injection: 1 Safety Precautions and Rules For Cleanliness

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CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...

24 – Mixture preparation - injection

1.1 General information on self-diagnosis

spring-type clips. The use of crimp-type or screw-type clips is

♦ For trouble-free operation of electrical components, a voltage

♦ Do not use sealants containing silicone. Particles of silicone

♦ The system also improves the starting characteristics of the

tivated for 2 seconds in order to build up pressure in the fuel

1. Safety precautions and rules for cleanliness 451

Assembly overview - high-pressure pump with fuel pressure reg‐

ulating valve - N276- ⇒ page 481 .

Removing and installing high-pressure pump ⇒ page 483 . spec

2.1 Technical data

CCZA, CCZB, CCZC, CCZD, CDAA, CDAB

Idling speed 1) rpm 640 to 800

Governed speed rpm approx. 6500

If voltage supply to engine control unit drops below 12 volt,

idling speed will be raised incrementally up to 990 rpm. The idling

speed cannot be adjusted.

452 Rep. gr.24 - Mixture preparation - injection

1 - Inlet camshaft control valve

❑ Removing and installing

- Golf, Eos ⇒ page 493

❑ Removing and installing - Tiguan ⇒ page 502

❑ Removing and installing - Scirocco ⇒ page 505

6 - High-pressure pump with fuel pressure regulating valve - N276-

Engine codes CCZA, CCZB, CCZC, CCZD ⇒ page 455

❑ Removing and installing ⇒ page 483

❑ Assembly overview - high pressure pump ⇒ page 481 .

7 - Fuel pressure regulating valve - N276-

Engine codes CCZA, CCZB, CCZC, CCZD ⇒ page 455

2. Injection system 453

8 - Radiator outlet coolant temperature sender - G83-

15 - 8-pin connector for injectors

⇒ Vehicle diagnostic tester

❑ One unit with non-return valve/throttle

❑ To remove and install, remove intake manifold

18 - Intake air temperature sender - G42-

454 Rep. gr.24 - Mixture preparation - injection

❑ Injector, cylinder 2 - N31-

❑ Injector, cylinder 3 - N32-

❑ Injector, cylinder 4 - N33-

1 - Fuel pressure regulating valve - N276-

2. Injection system 455

Hall sender - G40- -1-

456 Rep. gr.24 - Mixture preparation - injection

Below intake manifold (intake manifold is removed in illustration)

2. Injection system 457

Pay attention to installation position of turbocharger air recircula‐

2.3 Assembly overview - air filter

❑ Clean any salt residue,

leaves and dirt from up‐

per part of air filter

❑ Always use genuine

part for air filter element

❑ Removing and installing

❑ Not fitted in all vehicles.

10 - Air filter lower part

458 Rep. gr.24 - Mixture preparation - injection

12 - Water drain hose

2.4 Removing and installing air filter hous‐

– Detach air duct at bottom together with air hose.