24 - Mixture Preparation - Injection

Eos 2006 ➤ , Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran ...
4-cylinder injection engine (1.4 and 1.6 l direct injection) - Edition 04.2014
24 – Mixture preparation - injection

1 Injection system
General notes on injection ⇒ page 252 .
Technical data ⇒ page 253 .
Assembly overview - air filter ⇒ page 253 .
Removing and installing air filter ⇒ page 254 .
Assembly overview - intake manifold (engine codes BAG, BKG)
⇒ page 255
Assembly overview - intake manifold (engine codes BLF, BLN,
BLP) ⇒ page 258
Assembly overview - fuel rail with injectors ⇒ page 260 .
Cleaning throttle valve module - J338- ⇒ page 261 .
Removing and installing high-pressure pump (engine codes BAG,
BKG) ⇒ page 261
cardiagn.com
Removing and installing high-pressure pump (engine codes BLF,
BLN, BLP) ⇒ page 263
Removing and installing injectors ⇒ page 267 .
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1.1 General notes on injection d by
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♦ Fuel hoses in engine compartment must be ut secured only with
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spring-type clips which conform to production
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use of clamp or screw-type clips is not permissible.
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♦ The battery must be disconnected only with ignition switched

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off. If a coded radio is installed, ascertain code before discon‐
erm
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necting battery.
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♦ Observe required procedures after connecting battery ⇒ Elec‐

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trical system; Rep. gr. 27 ; Disconnecting and reconnecting

spec
urposes, in part or in wh
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♦ For trouble-free operation of electrical components, a voltage
of at least 11.5 V is necessary.
rrectne
♦ Do not use sealants containing silicone. Particles of silicone

drawn into the engine will not be burnt in the engine and dam‐
age the Lambda probe.
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♦ If, after fault finding, repairs or component tests, the engine

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starts, runs for a short period and then stops, then the fault
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may be that the immobilizer is blocking the engine control unit.

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In this case, the control unit must be adapted.

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♦ After completing work, read fault memory of engine control

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unit, clear all fault entries which may have been created during
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checks and repairs. If the fault memory was cleared, the read‐
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iness code must be generated ⇒ Vehicle diagnostic tester

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♦ Vehicles with an airbag are fitted with a crash fuel shut-off. It p by
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reduces the danger of a fire in a crash as the fuel pump is Prote
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switched off via the fuel pump relay.
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♦ When driver door is opened, the fuel pump is activated for 2

seconds to develop pressure in the fuel system. This improves
the quality of the start behaviour.
252 Rep. gr.24 - Mixture preparation - injection

1.2 Technical data

Engine codes BAG, BKG, BLN, BLP, BLF
Idling check
Idling speed18) rpm 630 … 73017)
Engine control unit
System Motronic MED 9.5.10
Governed speed rpm from approx. 5700
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17) Current values: ⇒ Exhaust emissionstho eo
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18) Not adjustable. ss
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1.3 Assembly overview - air filter
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Removing and installing air filter ⇒ page 254 .
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1 - Air filter housing lower part
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2 - Rubber bush
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3 - Filter element
4 - 3 Nm
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5 - Intake air temperature sen‐
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6 - O-ring
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7 - Air filter upper part
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❑ From camshaft housing.

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1. Injection system 253

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4-cylinder injection engine (1.4 and k1.6
swa l direct injection) - Edition
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1.4 Removing and installing air filter
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Air filter is integrated into engine cover.
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– Unclip intake hose connector -arrows-.
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– Pull hose -1- off air filter.

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– Pull connector -2- off intake air temperature sensor 2 - G299- . ht. Cop py
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– Pull out oil dipstick -1-.

– Pull cover off at positions marked by -arrows-.
Installing
– Seat rubber bushes for cover on securing pins on engine.
– Push cover downwards at positions marked by -arrows-.
– Fit oil dipstick -1- into guide tube to stop.

– Fit hose -1- onto air filter.
Note
The plug connector should click into place.
– Fit connector -2- onto intake air temperature sensor 2 - G299- .
– Clip on intake hose connector -arrows-.
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1.5 Assembly overview - intake manifold (engine
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1 - Return line
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❑ Secure with spring-type ed by
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❑ Check for secure seat‐ ss a ra
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❑ To fuel delivery unit in
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2 - Supply line
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❑ Secure with spring-type
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❑ Check for secure seat‐ es, in part or in w
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❑ From fuel filter.
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3 - Clip
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4 - Connecting pipe
5 - Fuel pressure sender for
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low-pressure - G410- , 18 Nm
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sure sender for low-pressure -

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❑ From model year 2006
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the O-ring has been dis‐

continued.
7 - 10 Nm
8 - Banjo bolt, 18 Nm
9 - Throttle valve module - J338-
❑ Clean ⇒ page 261 .
❑ If renewed, erase learnt values and adapt engine control unit ⇒ Vehicle diagnostic tester “Guided func‐
tions”.
10 - 10 Nm
11 - Seal
❑ Renew.
❑ Press in onto stop
12 - Retaining clip
13 - From activated charcoal filter system solenoid valve 1 - N80-
14 - Intake manifold
❑ Checking vacuum reservoir in intake manifold ⇒ page 272 .
15 - 8 Nm
16 - 5 Nm
17 - Connecting pipe
❑ For exhaust gas recirculation system.

18 - Fuel pressure sender - G247- , 20 Nm

19 - High-pressure line
20 - Banjo bolt, 18 Nm
21 - 20 Nm
22 - O-ring
❑ Renew (only versions with an O-ring)
23 - Intake manifold lower part
❑ When a new intake manifold lower part is fitted, the spacing sleeve for the injector is omitted
Caution
When installing lower
part of intake manifold,
ensure intake manifold
flaps are not damaged.
❑ Erase learnt values and adapt intake manifold flap potentiometer - G336- to engine control unit ⇒ Vehicle
diagnostic tester “Guided functions”.
cardiagn.com
❑ Before removing and installing, lock vacuum positioning element using a 2.5 mm drill bit.
❑ After installing a new lower part of intake manifold, remove retaining clip for vacuum positioning element.
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❑ After installing, check function ofointake oeshand vacuum pump - VAS 6213-
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⇒ page 272 . d byV gu
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❑ Note installation position.
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25 - 10 Nm
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26 - Intake manifold flap potentiometer - G336-

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❑ If renewed, erase learnt values and adapt engine control unit ⇒ Vehicle diagnostic tester “Guided func‐ h re
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27 - 1.5 Nm
28 - Vacuum actuator
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❑ For intake manifold flap

❑ Check ⇒ page 272 .
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29 - 20 Nm
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30 - Intake manifold pressure sender - G71-

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31 - 5 Nm
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32 - Intake manifold flap air flow control valve - N316-

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33 - Vacuum hose
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❑ To vacuum positioning element

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34 - 20 Nm
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35 - Vacuum hose co Vo
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❑ From intake manifold Prote AG.
36 - To activated charcoal filter solenoid valve 1 - N80-

37 - Activated charcoal filter solenoid valve 1 - N80-
38 - Return line
❑ Blue or with blue marking.
❑ Secure with spring-type clips.
❑ Check for secure seating.

1.6 Assembly overview - intake manifold

(engine codes BLF, BLN, BLP)
WARNING
Observe safety precautions when releasing fuel pressure

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From model year 2006 the fuel pressure sender for low-pressure
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- G410- has been discontinued.
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1 - Supply line
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clips.
❑ Check for secure seat‐
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ing.
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❑ From fuel filter.

2 - T piece
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3 - Fuel line
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❑ Pipe/hose
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4 - Throttle valve module -

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J338-
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❑ Clean ⇒ page 261 .

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❑ If renewed, erase learnt . Cop py
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“Guided functions”.
5 - 10 Nm
6 - From activated charcoal fil‐
ter
7 - Activated charcoal filter sol‐
enoid valve 1 - N80-
8 - Seal
❑ Renew.
❑ Press in onto stop
9 - From activated charcoal fil‐
ter system solenoid valve 1 -
N80-
10 - Intake manifold
❑ Checking vacuum res‐
ervoir in intake manifold
⇒ page 272 .
11 - 8 Nm
12 - 5 Nm
13 - Connecting pipe
❑ For exhaust gas recirculation system.

14 - Fuel pressure sender - G247- , 20 Nm

❑ Observe safety precautions when releasing fuel pressure in high-pressure section ⇒ page 164
15 - Union nut, 30 Nm
16 - 8 Nm
17 - High-pressure line
18 - Union nut, 25 Nm
Caution
When installing lower
part of intake manifold,
ensure intake manifold
flaps are not damaged.
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❑ Erase learnt values and adapt intake manifold flap potentiometer - G336- to engine control unit ⇒ Vehicle
diagnostic tester “Guided functions”. agen
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❑ Before removing and installing, by V lock vacuum positioning element
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❑ After installing a new tfuel
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❑ After installing, check
ss a function of intake manifold flap using hand vacuumc pump - VAS 6213-
⇒ page 272 .
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20 - Gasket
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❑ Renew.
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❑ Note installation position. wit

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21 - Intake manifold flap potentiometer - G336-
hole
spec
❑ If renewed, erase learnt values and adapt engine control unit ⇒ Vehicle diagnostic tester “Guided func‐
es, in part or in w
t to the co
tions”.
22 - 1.5 Nm
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23 - Vacuum actuator
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❑ For intake manifold flap

❑ Check ⇒ page 272 .
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24 - 2.2 Nm
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25 - 20 Nm
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26 - O-ring
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27 - Intake manifold pressure sender - G71-

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28 - 5 Nm
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29 - Intake manifold flap air flow control valve - N316-
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30 - Vacuum hose
❑ To vacuum positioning element
31 - Vacuum hose
❑ From intake manifold
32 - Return hose
❑ From fuel rail.
❑ Secure with spring-type clips.

33 - 20 Nm
1.7 Assembly overview - fuel rail with injectors
1 - Retaining clip
❑ Ensure correct seating
on injector and retaining
plate.
2 - O-ring
❑ Renew. AG. Volkswagen AG d
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❑ Before installing, mois‐ by Vol not
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3 - Spacer sleeve
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❑ When a new intake
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manifold lower part is fit‐
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4 - Injector, cylinder 4 - N33-
ole,
spec
❑ Injector, cylinder 1 -
N30-
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N31-
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N32-
ss
❑ Removing and installing
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⇒ page 267 .
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5 - Seal
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❑ Renew.
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6 - Vacuum hose
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7 - Return line um
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❑ From high-pressure
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clips.
8 - Pressure limiting valve
❑ Renew removed valve.
❑ Before installing lightly moisten O-rings with clean engine oil.
❑ Press in by hand using an 8 mm hexagon key.
9 - 20 Nm

Caution
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ensure intake manifold horis nte
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1.8 Cleaning throttle valve module - J338-
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Note es, in part or in w
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♦ If a new engine control unit is installed the throttle valve mod‐
ule must be adapted. Adaptation must be performed only with
a new or cleaned throttle valve module, because soiling or
rrectness of i
coking at the end stop of the throttle valve can lead to incorrect
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adaptation values.
♦ When cleaning the throttle valve housing it must not be
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– Remove air filter ⇒ page 254 .
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– Remove throttle valve module.
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– Open throttle valve by hand and lock in open position using a
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suitable object (e.g. wood or plastic wedge) -arrow-.
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Acetone is highly inflammable. Please observe the accidental
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regulations and safety notes when handling with highly inflam‐

mable fluids. Do not use compressed air when cleaning the
throttle valve. Wear eye protection and protective clothing to
avoid possible injury and skin contact.
– Thoroughly clean throttle valve housing, especially around the

closed throttle valve -arrows- using commercially available
acetone according to DIN 53247 and a brush.
– Wipe off throttle valve housing using a lint-free cloth.
– Allow acetone to evaporate completely and re-install throttle
valve module after cleaning.
– Erase learnt values and adapt engine control unit to throttle
valve module ⇒ Vehicle diagnostic tester “Guided functions”.
1.9 Removing and installing high-pressure

pump (engine codes BAG, BKG)
Special tools and workshop equipment required

♦ Torque wrench (4…20 Nm) with ratchet - V.A.G 1410-
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Prerequisite
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• Engine must be cold.
Removing
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WARNING
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Fuel system is under pressure! Wear eye protection and pro‐
om
tective clothing to avoid possible injury and skin contact. Before
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loosening hose connections, wrap a cloth around the connec‐
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– Remove connecting pipe -6- ⇒ page 302 .
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– Remove union nut -3-.
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– Remove banjo bolts -1-, -2- and -5-.
Note
Catch escaping fuel in a cloth.

– Pull off connector -1-.

– Pull fuel line connections -3- and -4- off high-pressure pump
-5-.
– Remove securing bolts -2-.
– Pull high-pressure pump -5- and bucket tappet
⇒ Item 21 (page 93) out of camshaft housing.
Installing
Installation is carried out in the reverse order. When installing,
note the following:
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– Push bucket tappet into camshaft housing.

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– Install high-pressure pump -5 -, with new oiled O-rings, in
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camshaft housing.
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– Tighten high-pressure pump -5- securing bolts -2- to 8 Nm.
hole
spec
– Reconnect connector -1-.
es, in part or in w
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– Reconnect fuel line connections -3- and -4- to high-pressure
pump.
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– Tighten banjo bolts -1- and -2- to 15 Nm.

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– Install high-pressure line -4- as follows:

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1 - Screw in banjo bolt -5- 2 full turns by hand.

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2 - Screw on union nut -3- to stop by hand.

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3 - Screw banjo bolt -5- onto stop by hand. t. C rig
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4 - Tighten banjo bolt -5- to 15 Nm.
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5 - Tighten union nut -3- to 15 Nm.
– Install connecting pipe -6- ⇒ page 302 .
– Install air filter ⇒ page 254 .
1.10 Removing and installing high-pressure

pump (engine codes BLF, BLN, BLP)

♦ Torque wrench (4…20 Nm) - V.A.G 1410-
♦ Spring-type clip pliers - VAS 5024A-
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Prerequisite
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• Engine must be cold.
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Removing
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WARNING
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Fuel supply lines are under pressure! Wear eye protection and
protective clothing to avoid possible injury and skin contact.
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Before loosening hose connections, wrap a cloth around the

connection. Then release pressure by carefully pulling hose off
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– Separate fuel supply line -arrow-.

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– Pull connector and fuel supply line -arrows- off high-pressure

pump.
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Catch escaping fuel in a cloth. nte
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– Remove wiring guide -2- and take clip -4- off high-pressure
hole
spec
line.
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Note
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Use a spanner to counterhold threaded connections on high pres‐
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sure pump and on lower part of intake manifold when loosening

union nuts.
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– Loosen union nuts -1- and -3- of high-pressure line.
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– Remove securing bolts -1-, -2- and -3- equally.

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– Pull high-pressure pump -3- and bucket tappet -1- out of cam‐
shaft housing.
Installing
Installation is carried out in the reverse order. When installing,
note the following:
Note
♦ Moisten high-pressure pump bucket tappet with clean engine

oil.
♦ The high-pressure pump O-ring must always be renewed.
– Push bucket tappet -1- into camshaft housing.

– Insert new, lubricated O-ring -2- in groove of high-pressure

pump -3-.
– Place high-pressure pump -3- onto camshaft housing.
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– Tighten securing bolts -1-, -2- and -3-bequally.
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Specified torque: 10 Nm
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– Tighten union nuts of high-pressure line -1- and -3- hand-tight.

– Install wiring guide -2- and fit clip -4- on high-pressure line.
Specified torque of wiring guide securing bolt: 8 Nm
Note
Use a spanner to counterhold threaded connections on high-

pressure pump and on lower part of intake manifold when tight‐
ening union nuts.
– Tighten union nut -1- of high-pressure line to 18 Nm.

– Tighten union nut -3- of high-pressure line to 18 Nm.

– Secure fuel supply line and connector -arrows- on high-pres‐

sure pump.
AG. Volkswagen AG d
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– Reconnect fuel supply line -arrow-.
spec
es, in part or in w
– Install air filter ⇒ page 254 .
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1.11 Removing and installing injectors
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Special tools and workshop

equipment required
♦ Torque wrench (5…50 Nm)
- V.A.G. 1331-
♦ Spring-type clip pliers -
VAS 5024A-
♦ Tool set for FSI engines -
T10133-
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1.11.1 Removing
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– Remove fuse for fuel pump from fuse holder. Fuse assignment
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⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐

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Note Prote AG.
For reasons of safety, the voltage supply to the fuel pump is in‐
terrupted through the removal of fuse. Otherwise opening the
driver door would start the fuel pump.
WARNING
Fuel system is under pressure! Wear eye protection and pro‐

tective clothing to avoid possible injury and skin contact. Before
loosening hose connections, wrap a cloth around the connec‐
tion. Then release pressure by carefully pulling hose off con‐
nection.
– Disconnect fuel lines -1- and -2- and line to activated charcoal
filter solenoid valve 1 - N80- -3-.

For engines with engine codes BLN, BLP and BLF only the fuel
supply line is installed (non-return fuel system).
– Seal lines so that fuel system is not contaminated by dirt.
Volkswagen AG
– Remove upper and lower parts of intake
swa
manifold.
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Engine codes thopage 258
BLP, BLF, BLNau⇒
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– Pull retaining clip and spacer sleeve off injector.
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– Set puller -T10133/1- on injector -1-. Ensure that puller hooks
h re
hole
engage into recesses of injector -arrows-.
spec
es, in part or in w
– Tighten knurled nut of puller hand-tight.
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rrectness of i
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– Screw slide hammer -T10133/3- onto -T10133/1- .

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– Pull injector carefully out of cylinder head by tapping gently.
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1.11.2 Installing
– Clean hole in cylinder head with nylon cylinder brush -
T10133/4- .

– Carefully clean injector in area of seal -arrow-. Remove carbon

deposits using a wire brush.
– Carefully cut open seal with a knife.
– Clean groove for seal.
– Attach assembly cone -T10133/5- with a new oil seal -1- to

injector -2-.
cardiagn.com
– Slide oil seal further onto assembly cone -T10133/6- using
assembly sleeve -T10133/5- .
– Turn assembly sleeve -T10133/6- and slide seal into groove
for seal.
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– Press calibration sleeve -T10133/7- onto injector to stop by

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turning gently (approx. 180°).

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– Pull off calibrating sleeve -T10133/7- by turning in opposite

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Prote AG.

– Press calibration sleeve -T10133/8- onto injector to stop by

turning gently (approx. 180°).
– Pull off calibrating sleeve -T10133/8- by turning in opposite
direction.
– Renew O-rings on injector and spacer sleeve.
– Before installing, moisten O-rings with clean engine oil.
Note
The seal must not be oiled.
– Insert injector into cylinder head.
Note
The injector must insert easily. If necessary wait until the seal has
contracted sufficiently.
cardiagn.com
– Install retaining clip and spacer sleeve.
Caution
When installing lower part of intake manifold, ensure intake

manifold flaps are not damaged.
Further assembly is basically the reverse of the dismantling se‐

quence.
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271
Prote AG.
1. Injection system
2 Checking components
Checking function of intake manifold flap ⇒ page 272
Checking vacuum reservoir in intake manifold for leaks
⇒ page 272
Checking intake air preheating ⇒ page 273 .
2.1 Checking function of intake manifold

flap
♦ Hand vacuum pump - VAS 6213-
AG. Volkswagen AG d
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Test procedure
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– After installing a new fuel rail, remove vacuum positioning el‐
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ement retaining clip -arrow-.
spec
es, in part or in w
– Connect hand-operated vacuum pump - VAS 6213- as shown.
t to the co
– Generate a vacuum and check function of vacuum positioning
element on lever arm.
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Note
nf
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When intake manifold is removed, the function of intake manifold

flap can be checked simultaneously. orm
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2.2 Checking vacuum reservoir in intake

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Test prerequisites
Perform visual check if all vacuum hoses on intake manifold are
not damaged and connected properly.
Test procedure
– Pull vacuum hose -arrow- between intake manifold flap valve
- N316- and intake manifold off intake manifold.
– Connect hand vacuum pump - VAS 6213- to intake manifold.

– Screw in knurled screw on hand vacuum pump - VAS 6213- .
cardiagn.com
– Operate hand vacuum pump until a vacuum of 0.3 bar is at‐
tained on pressure gauge.
AG. Volkswagen AG d
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Due to the high volume
rise in the vacuum reservoir, up to 20 strokes
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– Observe pressure approx. 3-5 minutes.

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If pressure of 0.3 bar is displayed:

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The vacuum reservoir in intake manifold is OK.

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If pressure drops:
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– Renew intake manifold.

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2.3 Checking intake air preheating

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♦ Chilling spray (commercially available)

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Checking regulating flap

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– Remove air intake connecting piece of air filter.

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– Check regulating flap position -1-.

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– Spray thermal element -2- with chilling spray.

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Note Prote AG.
The function of the thermal element can be checked simply by

spraying with commercially available chilling spray. The lower
part of the air filter must be removed for this purpose
⇒ page 254 .
2. Checking components 273

AG. Volkswagen AG d
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3 Engine control unit - J623- (Golf, Eos)
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Removing and
ss a installing engine control unit - J623- ⇒ page 274 ra
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Removing and installing engine control unit - J623- with protective

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spec
If you wish to renew the engine control unit, connect the ⇒ Vehicle
diagnostic testerVehicle diagnostic, testing and information sys‐
t to the co
tem and carry out the guided function “Renew control unit”.
Removing
rrectne
– Switch off ignition.
s
– Remove plenum chamber bulkhead ⇒ General body repairs;
s o
Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .
cial p
f inform
– Remove securing bolts -1- and remove cover plate -2-.
mer
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– Release front connector -1- from engine control unit and pull
it off.
– Lever up catch -2- slightly.
– Then press engine control unit out of retainer
-in direction of arrow-.
– Then release rear connector on engine control unit and pull it
off.
Installing
– Fit rear connector to engine control unit and lock in position.
– Push engine control unit onto bracket.
– Fit front connector to engine control unit and lock it in position.
– Install cover plate for connectors.

– Tighten securing bolts -1- to 10 Nm.

– If engine control unit has been renewed, erase learnt values
and adapt engine control unit ⇒ vehicle diagnosis tester “Gui‐
ded function”.
– Read fault memory, repair faults if necessary and then erase
fault memory ⇒ Vehicle diagnosis tester “Guided fault finding”.
– Install plenum chamber bulkhead ⇒ General body repairs;
– The readiness code will have to be created once the fault
memory has been deleted.
– Carry out a road test.
– Read control unit fault memory again.

unit - J623- with protective housing
♦ Electric cutter - V.A.G 1561A-
cardiagn.com
AG. Volkswagen AG d
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♦ Hot air blower from wiring harness repair set - VAS 1978A-
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♦ Grip pliers
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Note
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If the engine control unit is to be renewed, connect vehicle diag‐

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nostic, testing and information system - VAS 5051B- and perform

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“Renewing engine control unit” in guided functions.

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– Switch off ignition. cted agen
Prote AG.
3. Engine control unit J623 (Golf, Eos) 275

– Remove wiper arms, plenum chamber cover and plenum bulk‐

head ⇒ Electrical system; Rep. gr. 92 ; Windscreen wiper
system; Removing and installing windscreen wiper system .
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 (scorching/
melting of plastics etc.).
Perform settings on hot air blower -4- as shown:

– Turn temperature setting potentiometer -2- to maximum heat
output (600 °C).
cardiagn.com
– Set two-stage switch for volume of air -3- to position 3.
AG. Volkswagen AG d
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When shear-head bolts are heated up, parts of the protective
ise nte
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housing will be subjected auto
t
a large amount of heat. Wear pro‐ ra
c
tective gloves to avoid spossible injury.
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– Place nozzle of hot air blower close to shear-head bolt.

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– Switch on hot air blower and heat the bolts.

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– Remove bolts with grip pliers .

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spec
es, in part or in w
t to the co
Note
rrectness of i
If the bolts will not move, saw into heads of shear-head bolts so
l purpos
that two parallel slots are created -arrows- and then remove the
bolts.
nform
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Prote AG.

– Insert a screwdriver between protective housing -A- and

bracket -arrow-.
– Lever up protective housing using screwdriver -A- and pull to

side off bracket -arrow-.
AG. Volkswagen AG d
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– Release front connector -1- from engine control unit and pull
rm
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it off.
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– Lever up catch -2- slightly.
h re
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spec
– Then push engine control unit out of retainer -arrow-.
es, in part or in w
t to the co
– Then release rear connector on engine control unit and pull it
off.
Installing
rrectness of i
– Fit rear connector to engine control unit and lock in position.
l purpos
– Push engine control unit onto bracket.
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– Fit front connector to engine control unit and lock it in position.

m
– Push protective housing onto bracket. a

com
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– Tighten new shear-head bolts -1- evenly until heads shear-

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– Install plenum chamber bulkhead, plenum chamber cover and

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wiper arms ⇒ Electrical system; Rep. gr. 92 ; Windscreen Cop py
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Prote AG.
3. Engine control unit J623 (Golf, Eos) 277

4 Engine control unit - J623- (Golf Plus,

Touran)
Removing and installing engine control unit - J623- ⇒ page 278
Removing and installing engine control unit - J623- with protective
housing ⇒ page 279

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unit - J623- Volksw
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If you wish to renew the engine control unit, connect the ris ⇒ vehicle
e
tee
ho
diagnosis tester and perform the guided function “Renewing
au
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ac
trol unit”. ss
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– Loosen securing bolts -arrows- of control unit cover.
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t to the co
– Then remove securing nuts for control unit bracket -arrows-.
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– Release connectors on engine control unit and pull off con‐
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fo
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nector.
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Prote AG.
– Press catches -1- and -2- outwards. Then pull engine control
unit off control unit bracket in -direction of arrow-.
Installing
– Push engine control unit onto control unit bracket until it en‐
gages in catches.
– Fit connectors to engine control unit and lock in position.

– Tighten securing bolts -arrows- to 10 Nm.
– Tighten securing bolts -arrows- to 5 Nm.

ded function”.
– Read fault memory, repair faults if necessary
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– Install plenum chamber bulkhead ris ⇒ General body repairs;
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Rep. gr. 50 ; Body - front; aPlenum
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unit - J623- with protective housing
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♦ Nozzle attachment from wiring harness repair set - VAS 1978-
Prote AG.
If you wish to renew the engine control unit, connect the ⇒ vehicle
diagnosis tester and perform the guided function “Renewing con‐
trol unit”.
Removing
4. Engine control unit J623 (Golf Plus, Touran) 279

Note

Caution


output (600 °C).
cardiagn.com
WARNING

housing will be subjected to a large amount of heat. Wear pro‐
tective gloves to avoid possible injury.

– Switch on hot air blower and heat bolt for about 20 to 25 sec‐
onds.
– Unscrew shear-head bolt using mole grips on bolt head.
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– Then remove securingrisenuts nte
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– Release connectors on
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nector.
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Prote AG.

– Press catches -1- and -2- outwards. Then pull engine control
unit off control unit bracket in -direction of arrow-.
Installing
– Push engine control unit onto control unit bracket until it en‐
gages in catches.
– Fit connectors to engine control unit and lock in position.
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– Tighten securing bolts
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– Install cover riof
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– Read fault memory, repair faults if necessary and then erase

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fault memory ⇒ Vehicle diagnosis tester “Guided fault finding”.

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4. Engine control unit J623 (Golf Plus, Touran) 281

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4-cylinder injection engine (1.4 and
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5 Engine control unit - J623- (Passat)
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Removing and installing engine control unit - J623- ⇒ page 282
wit
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Removing and installing engine control unit - J623- with locking
spec
plate ⇒ page 283
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Removing and installing engine control unit - J623- with locking
clip ⇒ page 286
rrectne
unit - J623-
ss o
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form
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Removing
n
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t
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– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
r
fo
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ng
screen wiper system; Removing and installing wiper arms .

t.
yi Co
Cop py
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– Remove plenum chamber cover: ⇒ General body repairs, ex‐ ht. rig
rig ht
terior; Rep. gr. 64 ; Removing and installing plenum chamber
py by
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cover Prote
cted AG.
agen
– 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- in -direction of arrow-.
Installing

– 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.

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– Fit connectors to engine control ksw
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– Fit connector -1- tos auheated
t
windscreen control unit - J505- . or
ac
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– Install plenum chamber cover ⇒ General body repairs, exte‐
ce
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un
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rior; Rep. gr. 64 ; Removing and installing plenum chamber
an
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erm
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– Install wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
wit
is n
h re
ole,
spec
t to the co
unit - J623- with locking plate
rrectne
diagnosis tester and perform the guided function “Renewing con‐ ss o
trol unit”.
cial p
f inform

mer
atio
m
♦ Hot air blower from wiring harness repair set - VAS 1978-
o
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♦ Nozzle attachment from wiring harness repair set - VAS 1978-

Removing
– Remove plenum chamber cover: ⇒ General body repairs, ex‐
cover
5. Engine control unit J623 (Passat) 283

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4-cylinder injection engine (1.4 and
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Caution
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ss o
cial p
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mer
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n
output (600 °C).
c
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housing will be subjected to a large amount of heat. Wear pro‐
by c lksw
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tective gloves to avoid possible injury.
Prote AG.

– Switch on hot air blower and heat bolt for about 20 to 25 sec‐
onds.
– Unscrew shear-head bolt -2- using pliers on bolt head.
The procedure for the second shear-head bolt is identical.
– Pull connector -1- off heated windscreen control unit - J505- .
– Lift cover -1- and pull it forwards.

– Slide connector locking devices -1- on engine control unit out‐

– Remove retainer frame with engine control unit from plenum
chamber.
– Press locking device -1- outwards and slide engine control unit
-2- in -direction of arrow-.
Installing
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ility
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– Slide engine control unit -1- into retaining frame in h re

hole
spec
-direction of arrow-.
es, in part or in w
t to the co
– Fit retainer frame with engine control unit onto retainer in ple‐
num chamber.
Specified torque of securing nuts for retainer: 6 Nm.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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te
– Fit connectors to engine control unit and slide locking devices

a
do
riv
-1- inwards.
p
cum
for
en
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t.
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t. rig
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– Slide cover -1- over engine control unit and press it down‐
wards.
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du
an
itte
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ility
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– Tighten new shear-head bolts -2- evenly until bolt head shears
wit
, is n
off.
h re
hole
spec
– Fit connector -1- to heated windscreen control unit - J505- .
es, in part or in w
t to the co
– Install plenum chamber cover ⇒ General body repairs, exte‐
rior; Rep. gr. 64 ; Removing and installing plenum chamber
cover .
rrectness of i
– Install wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
cardiagn.com
l purpos
nform
mercia
at
om
ion
c
in t
or
his
e
unit - J623- with locking clip

at
do
priv
cum
or
f
en
ng
t.
yi
Co
op py
trol unit”. t. C rig
gh ht
pyri by
o Vo
by c lksw
cted agen
Prote AG.
♦ Grip pliers
Removing
– Remove plenum chamber cover: ⇒ General body repairs, ex‐
cover
– Remove 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.

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

– Remove shear-head bolts -2- using grip pliers and remove
locking clip.
AG. Volkswagen AG d
agen oes
olksw not
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– Slide connector locking devicesse-1-d on engine control unit out‐
b ara
nte
hori
eo
aut ra
c
– Remove engine control unit.
ss
ce
le
un
pt
Installing:
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
cardiagn.com
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Slide engine control unit -1- in direction of -arrow- in retaining
frame until it engages.
l purpos
– Tighten the retaining frame.
nform
ercia
Specified torque: 6 Nm
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
– Fit connectors to engine control unit and slide locking devices
by lksw
cted agen
-1- inwards.
Prote AG.
– Take a new locking clip and tighten new shear-head bolts

evenly until heads shear off.

24 - Mixture Preparation - Injection

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24 - Mixture Preparation - Injection

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Eos 2006 ➤ , Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran ...

24 – Mixture preparation - injection

♦ The battery must be disconnected only with ignition switched

♦ Observe required procedures after connecting battery ⇒ Elec‐

trical system; Rep. gr. 27 ; Disconnecting and reconnecting

♦ Do not use sealants containing silicone. Particles of silicone

♦ If, after fault finding, repairs or component tests, the engine

may be that the immobilizer is blocking the engine control unit.

In this case, the control unit must be adapted.

♦ After completing work, read fault memory of engine control

iness code must be generated ⇒ Vehicle diagnostic tester

♦ When driver door is opened, the fuel pump is activated for 2

252 Rep. gr.24 - Mixture preparation - injection

1.2 Technical data

❑ From camshaft housing.

1. Injection system 253

– Unclip intake hose connector -arrows-.

– Pull hose -1- off air filter.

– Pull out oil dipstick -1-.

– Fit oil dipstick -1- into guide tube to stop.

254 Rep. gr.24 - Mixture preparation - injection

– Fit hose -1- onto air filter.

The plug connector should click into place.

– Fit connector -2- onto intake air temperature sensor 2 - G299- .

– Clip on intake hose connector -arrows-.

1. Injection system 255

sure sender for low-pressure -

G410- has been discontinued.

the O-ring has been dis‐

256 Rep. gr.24 - Mixture preparation - injection

18 - Fuel pressure sender - G247- , 20 Nm

26 - Intake manifold flap potentiometer - G336-

❑ For intake manifold flap

30 - Intake manifold pressure sender - G71-

32 - Intake manifold flap air flow control valve - N316-

❑ To vacuum positioning element

36 - To activated charcoal filter solenoid valve 1 - N80-

1. Injection system 257

1.6 Assembly overview - intake manifold

Observe safety precautions when releasing fuel pressure

- G410- has been discontinued.

❑ From fuel filter.

4 - Throttle valve module -

❑ Clean ⇒ page 261 .

258 Rep. gr.24 - Mixture preparation - injection

14 - Fuel pressure sender - G247- , 20 Nm

❑ Note installation position. wit

❑ For intake manifold flap

27 - Intake manifold pressure sender - G71-

1. Injection system 259

1.7 Assembly overview - fuel rail with injectors

260 Rep. gr.24 - Mixture preparation - injection

suitable object (e.g. wood or plastic wedge) -arrow-.

regulations and safety notes when handling with highly inflam‐

– Thoroughly clean throttle valve housing, especially around the

1.9 Removing and installing high-pressure

1. Injection system 261

♦ Torque wrench (4…20 Nm) with ratchet - V.A.G 1410-

tective clothing to avoid possible injury and skin contact. Before

tion. Then release pressure by carefully pulling hose off con‐

Catch escaping fuel in a cloth.

262 Rep. gr.24 - Mixture preparation - injection