Seat Manual Leon FR 2008 BWA

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
4-cylinder injection engine (2.0 l engine, turbocharger) - Edition 08.2014
24 – Mixture preparation - injection

1 Injection system
General notes on injection ⇒ page 269 .
Safety precautions ⇒ page 139 .
Rules for cleanliness ⇒ page 142 .
Technical data ⇒ page 270 .
Assembly overview - intake manifold ⇒ page 273 .
Assembly overview - fuel rail (vehicles up to 05.2007)
⇒ page 280
Assembly overview - fuel rail (vehicles from 05.2007)
⇒ page 280
Assembly overview - air filter ⇒ page 270
Removing and installing engine cover/air filter ⇒ page 271
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Removing and installing air filter element ⇒ page 272
Removing and installing throttle valve module - J338-
⇒ page 284 wage
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Removing and installing fuel rail ⇒ page 283 .

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Removing and installing fuel pressure sender - G247-

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⇒ page 288 .
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Checking fuel pressure sender - G247- ⇒ page 290 .

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Removing and installing injectors ⇒ page 293 .

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Renew Teflon seal on injector ⇒ page 294
1.1 General notes on injection

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♦ Fuel hoses in engine compartment must be secured only with

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spring-type clips which conform to production standard. The

use of crimp-type 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‐

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♦ Observe required procedures after connecting battery ⇒ Elec‐

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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 by c lksw
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drawn into the engine will not be burnt in the engine and dam‐ Prote AG.
age the Lambda probe.
♦ If, after fault finding, repairs or component tests, the engine
starts, runs for a short period and then stops, then the fault
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
unit, clear all fault entries which may have been created during
checks and repairs. If the fault memory was cleared, the read‐
1. Injection system 269

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
iness code must be generated ⇒ Vehicle diagnostic tester

“Guided functions”.
♦ Vehicles with an airbag are fitted with a crash fuel shut-off. It
reduces the danger of a fire in a crash as the fuel pump is
switched off via the fuel pump relay.
♦ 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.
Safety precautions ⇒ page 139 .
Rules for cleanliness ⇒ page 142 .
Technical data ⇒ page 270 .
1.2 Technical data

Engine codes AXX, BWA, BPY
Idling check
Idling speed1) rpm 620…800
Engine control unit 2)
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System designation Motronic MED 9.1
Part number ⇒ ETKA (Electronic Parts Catalogue)
Governed speed rpm approx. 6,800
1) 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.
2) Renew engine control unit ⇒ page 298 . AG. Volkswagen AG d
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1.3 Assembly overview - engine cover/air filter by ara
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270 Rep. gr.24 - Mixture preparation - injection

AG. Volkswagen AG d Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
agen 4-cylinder injection
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1- Air mass
hor meter - G70- eo
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5 - Intake air duct
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6 - Filter element
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7 - Lower part of air filter
8 - 3 Nm
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9 - Heat shield
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10 - Rubber grommet
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❑ Observe fitting marks
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11 - Intake hose
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❑ Observe fitting marks

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1.4 Removing and installing engine cover/

air filter
Removing:
– Remove intake hose -1-.
– Pull off connector -2-.
– Remove bolts -3-.
– Pull engine cover off upwards in sequence -A…D- at points
indicated.
Installing:

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
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– Ensure that the four rubber mountings -arrows- are inserted in
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– Position engine cover in installation position and ho at the same
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time push the rubber mountings onto retaining ss
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Further installation is carried out in the reverse order.
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1.5 Removing and installing air filter ele‐
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ment
Removing:
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– Remove engine cover/air filter ⇒ page 271 .
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– Remove intake air duct -arrow-.
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– Remove all bolts -arrows-.
– Open engine cover (note retainers -arrows-).

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Pull air filter element out of engine cover.

Installing air filter element:
Note
♦ Always use genuine part for air filter element.

♦ The air filter housing must be clean.
♦ When blowing out the air filter housing with compressed air
note the following: to prevent malfunctions, cover air mass
meter - G70- with a clean cloth.
– Check air mass meter - G70- and intake air duct

⇒ Item 5 (page 271) for salt deposits, dirt and leaves.
– When installing the air filter element, check that it is properly
centred in the retainer in the lower part of the air filter. swa
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– Place upper part of air filter carefully on lower part of d bair filter
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Further installation is carried out in the reverse order.
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1.6 Assembly overview - intake manifold
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Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1 - 10 Nm
2 - Retaining clamp
3 - 3 Nm
4 - Stud, 10 Nm
5 - Gasket
❑ Renew
6 - Intake manifold
❑ With intake manifold
flaps
❑ Removing and installing
⇒ page 275 .
7 - Coupling rod lkswage es n
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⇒ page 278 .
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9 - 7 Nm
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10 - To activated charcoal filter
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11 - Hose
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12 - Activated charcoal filter
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13 - Hose
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14 - Dual non-return valve
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❑ Check ⇒ page 297 .
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15 - Intake manifold support
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17 - 10 Nm
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19 - Throttle valve module - J338-

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❑ Including throttle valve drive (electric throttle operation) - G186- , angle sender 1 for throttle valve drive C py
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(electric throttle operation) - G187- and angle sender 2 for throttle valve drive (electric throttle operation)
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❑ Removing and installing ⇒ page 284 .
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20 - 7 Nm
21 - Seal
❑ Renew if damaged
22 - 5 Nm
23 - Intake air temperature sender - G42-
24 - 10 Nm

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1.7 Removing and installing intake manifold

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Observe safety precautions when releasing fuel pressure in
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♦ Observe rules for cleanliness ⇒ page 142 .
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♦ If an injector was pulled out of the cylinder head when the in‐
take manifold was removed, the Teflon seal must be renewed
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⇒ page 294 .
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♦ Assembly overview - intake manifold ⇒ page 273 .
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– Remove throttle valve module - J338- ⇒ page 284 .
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– Disconnect all electrical connectors as necessary.
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– Disconnect vacuum hose between intake manifold and vac‐

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uum pump at intake manifold.

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♦ Wear eye protection and protective clothing to avoid pos‐ cted agen
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sible injury and skin contact.
♦ Before loosening line connections, wrap a cloth around
the connection. Then release pressure by carefully pulling
off line.
Engine code BPY:

– Disconnect lines -1, 2 and 3-. Do this by operating release
buttons.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Engine codes AXX, BWA

– Disconnect fuel supply line -2-.
– Disconnect breather line -2-.

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Continuation for all vehicles: lksw
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Pull vacuum lines -arrows- off intake manifold and cylinder head
cover.
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♦ Before loosening line connections, wrap a cloth around
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– Unscrew fuel pipe -4- from connection -3-. At the same time
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counterhold connection -3-. Prote AG.
– Unscrew banjo bolt -2-, at the same time counterhold connec‐

tion -1-.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Vehicles from 05.2006:

– Open hose clip -1- and pull fuel hose off.
– Unscrew fuel pipe -3-, at the same time counterhold connec‐
tion -2-.
Continuation for all vehicles:
– Disconnect coolant pipe and oil dipstick tube from intake mani‐ agen
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– Remove intake manifold support -arrows- and disconnect con‐
nector -1- from fuel pressure sender - G247- .
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– Unscrew all bolts from intake manifold.
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– Carefully pull intake manifold and fuel rail off cylinder head.
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If an injector was pulled out of the cylinder head when the intake
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manifold was removed, renew the Teflon seal of the injector
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⇒ page 294 .
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Renew O-rings between injector and fuel rail and moisten slightly Cop py
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Fit intake manifold with fuel rail on cylinder head and evenly press
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If the intake manifold flap motor - V157- or the intake manifold

were renewed, the intake manifold flap potentiometer - G336-
must be adapted to the engine control unit ⇒ Vehicle diagnostic
tester “guided functions”.
Specified torque Nm
Securing bolts for intake mani‐ 10
fold
Bolt for intake manifold support 23
Nut for intake manifold support 10
Fuel lines on high-pressure ⇒ page 285
pump
Bolts for intake manifold flap 7
motor - V157-

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1.8 Removing and installing intake manifold

flap motor - V157- and intake manifold
flap potentiometer - G336-
Special tools and workshop equipment required
♦ Assembly tool - T10118-
♦ Commercially available 1/4" drive ratchet handle e.g.. Hazet

2264
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♦ T30 bit insert

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Removing:
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– Unscrew air duct on lock carrier -arrows-.
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Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Pull off vacuum lines -arrows-.

– Remove connectors as follows:
Note
Use assembly tool - T10118- to facilitate release of connectors

which are less accessible
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♦ Connectorbyfor V intake manifold flap motor - oV157-
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♦ Connector
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♦ Connector for intake manifold pressure sender - G71- .

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♦ Connector for throttle valve module - J338-
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♦ Connector for fuel pressure sender for low pressure - G410-
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– Disconnect additional electrical connectors -arrows-.
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– Loosen cable retainer -A- and place complete wiring harness
t to the co
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– Unbolt retainer for connectors -arrows- from coolant pipe.

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♦ Plastic retainers are clipped.

♦ For clarity, the illustration shows the intake manifold removed
from the engine.
– Prise coupling rod -arrow- off intake manifold flap motor -

V157- .
– Unscrew bolts -1- and -2- using 1/4" drive ratchet handle and
T30 bit insert .

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Note
The rear bolt -arrow - can only be unscrewed with a ratchet han‐
dle . The space between the bolt and the coolant pipe is very
constricted.
– Remove intake manifold flap motor - V157- from intake mani‐

fold.
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– Insert bolts -1- and -2- by hand to prevent damage to the
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If the intake manifold flap motor - V157- or the intake manifold
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1.9 Assembly overview - fuel rail (vehicles
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up to 05.2006)
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Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1 - Injector, cylinder 1 - N30- to

injector, cylinder 4 - N33-
⇒ page 293 .
2 - 8 Nm
3 - Fuel rail
⇒ page 283 .
4 - Panel nut
5 - Pressure limiting valve
❑ 30 Nm
❑ To remove and install,
remove intake manifold
⇒ page 275 .
6 - Low pressure pipe
❑ When removing, coun‐
terhold pressure limiting
valve
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❑ Before installing, check
pressure of pressure
limiting valve.
❑ Install free of tension.
❑ Tighten union nut to lkswage es n
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7 - Bracket auth or
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8 - High-pressure pipe
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❑ Tighten fuel rail union
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9 - Connector
❑ For injectors.
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10 - 5 Nm
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11 - Fuel pressure sender - G247-

❑ 22 Nm
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❑ Coat thread and sealing taper with clean engine oil.

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Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1 - Injector, cylinder 1 - N30- to

injector, cylinder 4 - N33-
⇒ page 293 .
2 - 8 Nm
3 - Fuel rail
⇒ page 283 .
4 - Low pressure fuel hose
❑ To high-pressure pump
5 - Pressure limiting valve
❑ 30 Nm
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7 - Low pressure pipe
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❑ Tighten union nut to
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8 - Bracket
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❑ Counterhold threaded
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12 - Connector
❑ For ⇒ Item 16 (page 282) and ⇒ Item 17 (page 282)
13 - Connector
❑ For ⇒ Item 11 (page 282)
14 - Cable channel
15 - Clip
❑ Attach on lower right sleeve of intake manifold
16 - Connector
❑ For Hall sender - G40- .
17 - Connector
❑ For fuel pressure sender - G247- .

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
18 - 5 Nm
19 - Fuel pressure sender - G247-
❑ 22 Nm
❑ Coat thread and sealing taper with clean engine oil.
20 - Threaded connection
❑ 30 Nm
1.11 Removing and installing fuel rail

Removing:
– Remove intake manifold ⇒ page 275 .
– Remove hoses from activated charcoal filter.
– To do this, open hose clip -1-.
– Unscrew two bolts -arrows- on fuel rail.
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– Disconnect union nuts of the two fuel pipestho -2 and 3-. At the eo
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– Carefully pry off linkage from intake manifold flap motor -

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– Unbolt intake manifold flap motor - V157- -5-.

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– Remove fuel rail from intake manifold.

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Installing:
– Install in reverse order.
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Specified torques (vehicles to 05.2006) ⇒ page 280 .

inform
mer
Specified torques (vehicles from 05.2006) ⇒ page 281 .

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cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1.12 Removing and installing throttle valve

module - J338-
Removing:
Golf:
– Remove pipe -A- and hose -B- -arrows-.
All vehicles:
cardiagn.com
– Loosen hose clip -1-.
– Remove bolt -2-. lkswage es n
o ot g
byV ua
d
– Remove noise insulation ⇒ Generalo
ir se body repairs, exterior;
ran
tee
Rep. gr. 50 ; Noise insulation auth or
ac
ss
– Disconnect electrical connector -3-.
ce
e
nl
pt
du
an
– Remove bolt -4- pull air pipe off charge air cooler and take
itte
y li
downwards.
erm
ab
ility
ot p
– Remove four bolts of throttle valve module - J338- and remove

wit
, is n
throttle valve module - J338- . h re

hole
spec
Installing:
es, in part or in w
t to the co

note the following:
rrectness of i
– If a new throttle valve module - J338- was installed, adapt the

engine control unit to throttle valve module - J338- ⇒ Vehicle
l purpos
diagnostic tester “guided functions”.

nf
ercia
1.13 Cleaning throttle valve module - J338-

rm
m
atio
om

n in
or c
thi
e
♦ Acetone
t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi
Note
Co
Cop py
t. rig
gh ht
yri
♦ Always follow safety precautions ⇒ page 139 .
p by
co Vo
by lksw
cted agen
Prote AG.
♦ When cleaning the throttle valve housing it must not be

scratched.
Procedure:
– Remove throttle valve module ⇒ page 284 .

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Open throttle valve by hand and block throttle valve in open

position with a suitable object -arrow-.
WARNING
Acetone is highly inflammable. Please observe the accidental

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

closed throttle valve, using commercially available acetone
and a cleaning brush.
– Wipe off throttle valve housing using a lint-free cloth.
– Allow acetone to evaporate completely and re-install throttle
valve module after cleaning.
– Adapt the engine control unit to throttle valve module ⇒ Vehicle
cardiagn.com
diagnostic tester “Guided functions”.
1.14 Assembly overview - high-pressure

. Volkswagen AG
pump
Vol
kswagen AG does
not
by gu
ara
ed nte
oris eo
th
Note
au ra
c
ss
ce
e
nl
pt
From 05.2006 on the low pressure line on high-pressure pump,

du
an
itte
the pipe with banjo bolt was replaced by a hose connection with
y li
erm
ab
spring-type clip.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1 - Plunger
❑ Renew if damaged
2 - O-ring
❑ Renew
❑ Before installing, mois‐
ten lightly with clean en‐
gine oil.
3 - High-pressure pump with
fuel pressure regulating valve -
N276-
⇒ page 287 .
4 - 10 Nm
5 - Union nut
❑ 27 Nm
❑ When loosening, coun‐
terhold threaded con‐
nection
cardiagn.com
❑ Before installing, check gen AG. Volkswagen AG d
torque of threaded Vcon‐ wa oes
olks not
gu
nection in high-pressure
ed by ara
nte
pump horis
eo
ut ra
❑ Install fuel
ss a
pipe free of c
tension.
ce
e
nl
pt
du
an
itte
y li
erm
ab
❑ Observe safety precau‐

ility
ot p
tions when releasing

wit
, is n
fuel pressure in high-

h re
pressure section
hole
spec
⇒ page 140
es, in part or in w
t to the co
❑ Vehicles from 05.2006
rrectness of i
❑ 30 Nm
❑ Only renew if loosened.
l purpos
❑ Always leave old seal in high-pressure pump when renewing threaded connection. When initially installed
at the factory, it is crushed and cannot be removed. To seal, the new threaded connection is fitted with
nform
ercia
a »grip edge«.
m
at
om
8 - Low pressure fuel hose

ion
c
in t
r
❑ Vehicles from 05.2006

o
his
ate
❑ Secure with spring-type clip.

do
priv
cum
or
9 - Banjo bolt with conical sealing seat

f
en
ng
t.
yi Co
❑ 15 Nm t. Cop py
rig
gh
❑ Renew
ht
pyri by
Vo
o
by c lksw
❑ Install fuel pipe free of tension. Prote
cted AG.
agen
❑ When loosening, counterhold threaded connection

❑ Vehicles up to 05.2006
10 - Fuel pipe
❑ Low-pressure.
❑ 30 Nm

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
❑ Only renew if loosened.
❑ Always leave old seal in high-pressure pump when renewing threaded connection. When initially installed
at the factory, it is crushed and cannot be removed. To seal, the new threaded connection is fitted with
a »grip edge«.
12 - Threaded connection for high-pressure pipe
❑ 40 Nm
❑ Do not loosen threaded connection, only retighten
13 - Fuel pressure sender for low-pressure - G410-
❑ 15 Nm
14 - Seal
❑ Renew
1.15 Removing and installing high-pressure

pump
WARNING
cardiagn.com
♦ Observe safety precautions when releasing fuel pressure
in high-pressure section ⇒ page 140
♦ For safety reasons, the fuse for the fuelspumpagen must be
AG. Volkswagen AG d
oes
k w
removed before opening the fuel system
by Vol ⇒ page 139 . not
gu
Otherwise, the fuel pump couldrisbe
e activated by the driver
d ara
nte
door contact switch. ut
ho eo
r
a ac
ss
ce
le
un
pt
an
d
itte
y li
Note
rm
ab
pe
ility
ot
wit
♦ The high-pressure pump must not be dismantled.
, is n
h re
hole
♦ Note safety precautions before beginning work ⇒ page 139 . spec

es, in part or in w

t to the co
Removing:
rrectness of i

l purpos
– Set engine to TDC.

nform
ercia
– Pull off connectors -1 and 2-.

m
a
com
tio
WARNING
n in
r
te o
thi
s

iva
do
r
rp
cum
♦ Wear eye protection and protective clothing to avoid pos‐

fo
en
ng

t.
yi Co
Cop py
t. rig
♦ Before loosening line connections, wrap a cloth around gh ht
yri by
the connection. Then release pressure by carefully pulling cop Vo
by lksw
off line.
cted agen
Prote AG.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Vehicles up to 05.2006:
– Unscrew fuel pipe -4- from connection -3-. At the same time
counterhold connection -3-.
– Unscrew banjo bolt -2-, at the same time counterhold connec‐
tion -1-.
Vehicles from 05.2006:

– Open hose clip -1- and pull fuel hose off.
– Unscrew fuel pipe -3-, at the same time counterhold connec‐
tion -2-.
Continuation for all vehicles: lkswage es n
o ot g
byV ua
d ran
ir se tee
cardiagn.com
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
– Remove bolts -arrows- and carefully remove high-pressure
wit
, is n
pump.
h re
hole
spec
es, in part or in w
t to the co
Note
Under certain circumstances, the plunger ⇒ Item 1 (page 286)
rrectness of i
may become stuck in the cylinder head.
l purpos
Installing: nform
ercia
– Renew O-ring for high-pressure pump (lubricate lightly with

clean engine oil before fitting).
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a
com
tio
– Check plunger ⇒ Item 1 (page 286) for damage and insert in

n in
r
cylinder head.
te o
thi
s
iva
do
r
rp
– Carefully place high-pressure pump in position on cylinder

um
fo
en
head and tighten bolts -arrows- hand tight.

ng
t.
yi Co
op py
– Bolt on fuel pipes hand-tight. t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
Note
AG.
Before installing fuel pipes, check torque for threaded unions.
– Then tighten all bolts and fuel pipes to specified torque

⇒ page 285 .
– Reconnect current supply.
Further installation is performed in the reverse sequence.
1.16 Removing and installing fuel pressure

sender - G247-

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Double hexagon socket, 27 mm - VAS 5301/7-
rrectness of i
WARNING
l purpos
♦ Observe safety precautions when releasing fuel pressure

in high-pressure section ⇒ page 140
nform
ercia
♦ For safety reasons, the fuse for the fuel pump must be
cardiagn.com
m
removed before opening the fuel system ⇒ page 139 .
at
om
io
Otherwise, the fuel pump could be activated by the driver
n
c
in t
door contact switch.
or
his
ate
do
priv
cum
or
Removing:
f
en
ng
t.
yi Co
op
C py
t. rig
gh ht
yri by
– Remove coolant pipe and oil dipstick tube from intake manifold cop Vo
by lksw
-arrows-.
cted agen
Prote AG.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Push oil dipstick tube downwards to right -arrow-.

– Release connector from fuel pressure sender - G247- using
assembly tool - T10118- .
WARNING
swage es n
The fuel rail is pressurized. Wear eye protection
byV
olk
and protective ot g
ua
clothing to avoid possible injury andir seskin contact. Before loos‐
d ran
tee
ening the fuel pressure sender a-uG247-
tho
wrap a cloth around the or
connection. Then release pressure
ss by carefully loosening the ac
connection.
ce
le
un
pt
an
d
itte
y li
rm
ab
– Unscrew fuel pressure sender - G247- using deep hexagon
pe
ility
ot
socket, 27 mm - VAS 5301/7- .
wit
, is n
h re
Installing:
hole
spec
es, in part or in w
t to the co
note the following:
Specified torques ⇒ Item 19 (page 283) .
rrectness of i
cardiagn.com
1.17 Checking fuel pressure sender - G247-
l purpos
nform
ercia

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Double hexagon socket, 27 mm - VAS 5301/7-

♦ Pressure sensor tester - VAS 6394-
♦ Test adapter - VAS 5570-

wage es n
yV
olks Eos 2006 ➤ , Golf ot 2004
gu ➤ , Passat 2006 ➤
b
4-cylinderriinjection
se
d engine (2.0 l engine, turbocharger)
ara
nte - Edition 08.2014
ho eo
aut ra
Procedure: ss c
ce
e
nl
pt
du
an
itte
WARNING
y li
erm
ab
ility
ot p
♦ The fuel pressure sender is under pressure! Wear eye
wit
, is n
protection and protective clothing to avoid possible injury
h re
and skin contact. Before loosening fuel pressure sender,
hole
spec
wrap a cloth around the connection. Then release pres‐
es, in part or in w
sure by carefully loosening the connection.
t to the co
rrectness of i
– Remove fuel pressure sender - G247- ⇒ page 288
– Unscrew plug -2- and screw fuel pressure sender - G247- into
l purpos
tester - VAS 6394/1- . Specified torque 22 Nm.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
cardiagn.com
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Moisten tapered seal of adapter - VAS 6294/2- with clean en‐
gine oil and screw into fuel rail. Specified torque: 22 Nm.
– Connect pressure line of tester - VAS 6394/1- to adapter - VAS

6394/2- .
– Connect fuel pressure sender -1- and electrical connector of
fuel pressure sender using test instrument adapter - VAS
5570- .
– Install engine cover/air filter again and reconnect the air mass
meter - G70- .

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
4-cylinder injection engine (2.0 l engine, turbocharger) - Edition
olksw
08.2014
AG. V agen AG
agen does
lksw not
– Switch on tester - VAS 6394/1- to do this, press button
db
y V -A- once
o gu
ara
briefly. rise nte
tho eo
s au ra
c
s
ce
e
Note
nl
pt
du
an
itte
y li
♦ When button -A- is pressed for 2 seconds, the illumination will
erm
ab
ility
be switched on for 20 seconds.
ot p
wit
, is n
♦ If the pressure tester - VAS 6394/1- reading is not 0 bar, carry
h re
hole
out a zero point procedure ⇒ operating instructions .
spec
es, in part or in w
t to the co
– Connect vehicle diagnostic tester to diagnostic connection.
– Switch on ignition.
rrectness of i
– Press following buttons on display of diagnostic tester one af‐
l purpos
ter the other:

Vehicle self-diagnosis
nform
ercia
Self-diagnosis ►
m
at
om
io
01 - Engine electronics ►
n
c
in t
or
cardiagn.com
his
te
011 - Measured values ►

a
do
priv
c
– Select measured value block 1 4 0 and confirm with Q .
um
for
en
ng
t.
yi
The actual fuel pressure value is shown in display zone 3, meas‐
Co
Cop py
ured by the fuel pressure sender - G247- .
t. rig
gh ht
pyri by
Vo
o
– Start engine. by c lksw
cted agen
Prote AG.
– Compare the displayed pressure of pressure tester - VAS
6394/1- with the displayed actual value on vehicle diagnostic
tester .
• A maximum pressure deviation of 5 bar is permissible.
– If the deviation is greater than 5 bar, renew fuel pressure
sender - G247- .
WARNING
The tester - VAS 6394- is under extreme fuel pressure! With

engine running, pull connector off fuel pressure sender -
G247- . This reduces fuel pressure to approx. 6 bar. Switch off
ignition. Place a cleaning cloth around fuel pressure sender -
G247- , then reduce residual pressure by carefully loosening
fuel pressure sender - G247- .
– Repeat the test with the new fuel pressure sender - G247- and
compare both measured values.
If measured values again fail to correspond:
– Check wiring ⇒ Vehicle diagnostic tester.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1.18 Removing and installing injectors

Special tools and work‐
shop equipment re‐
quired
♦ Tool set - T10133-
Injector components
1- Radial compensa‐
cardiagn.com
tion element (re‐
new)
2- Combustion cham‐
ber ring seal (Tef‐
lon ring seal) - re‐
new; when fitting,
AG. Volkswagen AG d
do not grease ring lksw
agen oes
not
or use any other lu‐ byV
o gu
ara
bricant orised
nte
h eo
ut ra
3- Groove in injector. ss a c
ce
e
4- Support washer
nl
pt
du
an
(renew).
itte
y li
erm
ab
5- O-ring (renew; to
ility
ot p
install, lightly lubri‐

wit
, is n
cate with clean en‐

h re
hole
gine oil).
spec
es, in part or in w
6- Support ring
t to the co
Removing:
– Remove intake mani‐
rrectness of i
fold ⇒ page 275 .

l purpos
– Seal intake ports with

a clean cloth.
nf
ercia
orm
m
– Use a screwdriver to bend retaining hooks of radial compen‐

atio
m
sation element to side, and pull support ring off injector.

o
n in
or c
thi
te
sd
iva
o
r
Note
rp
cu
o
m
f
en
ng
t.
yi
The retaining hooks of radial compensation element are damaged
Co
Cop py
by this action (retaining hooks bend or break). The radial com‐ ht. rig
rig ht
pensation element must be renewed before injector is refitted. py by
co Vo
by lksw
cted agen
Prote AG.

agen AG olksw
Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤ wage
n AG. V does
olks not
4-cylinder injection engine (2.0 l engine, turbocharger)
d by V - Edition 08.2014 gu
a
e ran
ris tee
ho
– Screw slide hammer - T10133/3- to puller - aT10133/2-
ut . Then or
ac
guide puller - T10133/2- into groove in injector
ss and carefully
ce
e
hammer injector out.
nl
pt
du
an
itte
y li
Installing:
erm
ab
ility
ot p
wit
, is n
Note
h re
hole
spec
♦ The Teflon seal on the injector must not be oiled or greased.
es, in part or in w
t to the co
♦ It is possible that an open inlet valve hinders cleaning. In this
case, turn engine by hand at crankshaft using a spanner.
rrectness of i
l purpos
– Thoroughly clean holes of high-pressure injectors in cylinder

head using a nylon brush - T10133/4- .
nform
ercia
– Renew O-ring, radial compensation element, support washer

and Teflon seal of injector ⇒ page 294 .
m
at
om
ion
c
in t
or
his
ate
do
priv
cardiagn.com
um
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Insert injector in hole in cylinder head to stop using drift -
T10133/9- .
– Ensure correct position of injectors in cylinder head.
1.19 Renewing Teflon seal on injector


Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
♦ Tool set - T10133-
Note
The Teflon ring must not be lubricated.
– Carefully clean injector in area of seal -arrow-. Remove coking

deposits using a brass wire brush.
cardiagn.com
– Carefully cut open seal with a knife.
– Clean groove for seal.
AG. Volkswagen AG d
agen oes
olksw not
V
– Fit new sealedonto
by assembly cone - T10133/5- . gPush ua
ran seal as
far as possible
horis onto assembly sleeve - T10133/6- using tee as‐
sembly autcone - T10133/5- . or
ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Turn assembly sleeve - T10133/6- around and push seal to

end of assembly cone - T10133/5- .
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Fit assembly cone - T10133/5- onto injector and push seal on‐
to injector using assembly sleeve - T10133/6- .
– Remove assembly cone - T10133/5- and push seal into
groove using assembly sleeve - T10133/6- .
– Push calibration sleeve - T10133/7- onto injector to stop with

a gentle twisting motion (approx. 180°).
– Pull calibration sleeve - T10133/7- off again by turning it in the
opposite direction.
swage es n
cardiagn.com
olk ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
– Now press calibration sleeve - T10133/8- onto injector to stop
rm
ab
by turning gently (approx. 180°).
pe
ility
ot
wit
, is n
– Pull calibration sleeve - T10133/8- off again by turning it in the

opposite direction. h re
hole
spec
es, in part or in w
– Renew O-ring on injector and on support washer.

t to the co
rrectness of i
l purpos
nform
ercia
– Attach support ring -1- to injector and clip radial compensation

m
a
com
-2- into support ring.

ion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
2 Checking components
Checking double non-return valve
♦ Hand vacuum pump - VAS 6213-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
– Remove connectors from activated charcoal filterutsolenoid
ho eo
ra
valve 1 - N80- and fuel pressure sender for low-pressure
s a - c
cardiagn.com
s
G410- -arrows-.
ce
le
un
pt
an
d
– Remove activated charcoal filter solenoid valve 1 - N80- -B-

itte
y li
erm
from hose -A-.
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Move slide ring -1- on hand vacuum pump - VAS 6213- to po‐
s
sition -A- (vacuum).
s o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Connect hand vacuum pump - VAS 6213- to hose to double
non-return valve -arrow-.
– Operate hand vacuum pump - VAS 6213- several times, vac‐
uum must build up.
If no vacuum builds up, renew double non-return valve.
2. Checking components 297

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
3 Engine control unit - J623- , Golf, Eos

Removing and installing engine control unit - J623- ⇒ page 298
Removing and installing anti-theft engine control unit - J623-
⇒ page 298
wage
3.1 Removing and installing engine control byV
olks es n
ot g
ua
unit - J623- ho
ir se
d ran
tee
ut or
a ac
ss
ce
e
Note
nl
pt
du
an
itte
y li
erm
If you wish to renew the engine control unit, connect the vehicle
ab
ility
diagnostic tester and perform the guided function “Renewing en‐
ot p
wit
gine control unit”.
, is n
h re
hole
spec
Removing
es, in part or in w
t to the co
– Switch off ignition.
– Remove wiper arms, plenum chamber cover and plenum
rrectness of i
cardiagn.com
chamber bulkhead: ⇒ Electrical system; Rep. gr. 92 ; Wind‐
screen wiper system; Removing and installing windscreen
l purpos
wiper system .
– Release front connector -1- from engine control unit and pull
nf
ercia
it off.
orm
m
atio
m
– Lever up catch -2- slightly.

o
n in
or c
– Then push engine control unit out of retainer -arrow-.
thi
te
sd
iva
– Then release rear connector on engine control unit and pull it
o
r
rp
cu
off.
o
m
f
en
ng
t.
yi Co
Installing Cop py
t. rig
gh ht
yri
– Fit rear connector to engine control unit and lock in position. p by
co Vo
by lksw
cted agen
– Push engine control unit onto bracket. Prote AG.
– Fit front connector to engine control unit and lock it in position.

– Install plenum chamber bulkhead, plenum chamber cover and
wiper arms ⇒ Electrical system; Rep. gr. 92 ; Windscreen
wiper system; Removing and installing windscreen wiper sys‐
tem .
3.2 Removing and installing anti-theft en‐

gine control unit - J623-
♦ Electric cutter - V.A.G 1561 A-
♦ Saw set - V.A.G 1561/14-

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
♦ Grip pliers
♦ Hot air blower from wiring harness repair set - VAS 1978-
cardiagn.com
Note
If the engine control unit is to be renewed, connect Vehicle AG. Vdiag‐

olkswagen AG
agen
nostic, testing and information system - VAS 5051B- ksw and carry
does
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Removing: ss
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– Remove wiper arms, plenum chamber cover and plenum

erm
ab
chamber bulkhead: ⇒ Electrical system; Rep. gr. 92 ; Wind‐

ility
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screen wiper system; Removing and installing windscreen

wit
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wiper system .
h re
hole
spec
es, in part or in w
t to the co
Note
The shear-head bolt threads are coated with locking compound.

rrectness of i
Heating the shear-head bolt with a hot air blower releases the
locking effect of the locking compound.
l purpos
nform
ercia
Caution
m
at
om
Cover lines, connections and control units in the vicinity of the

on
c
in t
engine control unit to prevent damage through heat (scorching/

or
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e
melting of plastics etc.).

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Perform settings on hot air blower -4- as shown:
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3. Engine control unit J623 , Golf, Eos 299

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
AG. Volkswagen G d
4-cylinder injection engine
lkswagen(2.0 l engine, A
turbocharger)
oes
n - Edition 08.2014
o ot g
yV ua
edb ran
– Turn temperaturehorsetting
is potentiometer -2- to maximum heat tee
output (600°C).aut or
ac
ss
– Set two-stage switch for volume of air -3- to position 3.
ce
e
nl
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erm
ab
WARNING
ility
ot p
wit
, is n
When shear-head bolts are heated up, parts of the protective
h re
housing will be subjected to a large amount of heat. Wear pro‐
hole
spec
tective gloves to avoid possible injury.
es, in part or in w
t to the co
– Place nozzle of hot air blower close to shear-head bolt.
rrectness of i
– Switch on hot air blower and heat the bolts.
l purpos
– Remove bolts with grip pliers .
nf
ercia
orm
m
Note
atio
om
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If the bolts will not move, saw into heads of shear-head bolts so
thi
te
sd
that two parallel slots are created -arrows- and then remove the
a
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iv
o
r
bolts.
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– Insert a screwdriver between protective housing -A- and

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

side off bracket -arrow-.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Release front connector ge-1-

n AGfrom
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wagen AG
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ss engine control unit out of retainer -arrow-.
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– Then release rear connector on engine control unit and pull it
du
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Installing:
ot p
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– Fit rear connector to engine control unit and lock in position.
h re
hole
spec
– Push engine control unit onto bracket.
es, in part or in w
t to the co
– Fit front connector to engine control unit and lock it in position.
– Push protective housing onto bracket.
rrectness of i
– Tighten new shear-head bolts -1- evenly until heads shear off.
l purpos
– Install plenum chamber bulkhead, plenum chamber cover and

wiper arms ⇒ Electrical system; Rep. gr. 92 ; Windscreen
nform
ercia
wiper system; Removing and installing windscreen wiper sys‐

m
tem .
at
om
io
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3. Engine control unit J623 , Golf, Eos 301

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
4 Engine control unit - J623- (Passat)
Note
From November 2006 a modified anti-theft protection has been

introduced. Identification: Locking clip instead of locking plate
Removing and installing engine control unit - J623- ⇒ page 302

Removing and installing anti-theft engine control unit - J623- (with
locking plate) ⇒ page 303
Removing and installing anti-theft engine control unit - J623- (with
locking plate) ⇒ page 307
4.1 Removing and installing engine control

unit - J623-
Note
cardiagn.com
DANGER!
For vehicles with heavy duty running gear; vehicle must be re‐
stricted to a maximum of 210 km/h via the engine control unit.
Drive shafts can be damaged at speeds above 210 km/h. Per‐
form function “Restricting maximum speed” in Guided function
using Vehicle diagnostic tester.
AG. Volkswagen AG d
agen oes
ksw not
Removing: by
Vol
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– Switch off ignition. ut
hor eo
a ra
s c
– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐ s
ce
e
screen wiper system; Removing and installing wiper arms .

nl
pt
du
an
itte
y li
– Remove plenum chamber cover ⇒ General body repairs, ex‐

erm
ab
terior; Rep. gr. 64 ; Flush-bonded windows; Assembly over‐

ility
ot p
view - plenum chamber cover .

wit
, is n
h re
– Pull connector -1- off heated windscreen control unit - J505- .

hole
spec
es, in part or in w
– Slide connector locking devices -2- on engine control unit out‐

t to the co
wards and pull off both connectors.

– Remove securing bolts -3-.
rrectness of i
– Remove retainer frame with engine control unit from plenum

chamber.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
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for
en
ng
t.
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pyri by
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cted agen
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302
AG.
Rep. gr.24 - Mixture preparation - injection
Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Press locking device -1- outwards and slide engine control unit
-2- from retaining frame.
Installing:
– Slide engine control unit -1- into retaining frame in direction of

arrow. n AG. Volkswagen AG
wage does
olks not
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t to the co
– Fit retainer frame with engine control unit onto retainer -4-.
Specified torque of securing nuts for retainer: 6 Nm.
– Tighten securing bolts -3- to 7 Nm. rrectne
– Fit connectors to engine control unit and slide locking devices

ss
-2- inwards.
o
cial p
f inform
– Fit connector -1- to heated windscreen control unit - J505- .

mer
atio
– Install plenum chamber cover ⇒ General body repairs, exte‐

om
rior; Rep. gr. 64 ; Flush-bonded windows; Assembly overview

c
i
or
- plenum chamber cover .

thi
te
sd
iva
– Install wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐

pr
cum
r
fo
screen wiper system; Removing and installing wiper arms.

en
ng
t.
yi Co
Cop py
.
t rig
gh ht
pyri by
Vo
o
gine control unit - J623- (with locking
c by lksw
cted agen
Prote AG.
plate)
Note
DANGER!
4. Engine control unit J623 (Passat) 303

AG. Volkswagen AG d
agen oes
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V gu
d by ara
Eos 2006 ➤ oris , Golf 2004 ➤ , Passat 2006 ➤
e nte
h e
4-cylinderaut injection engine (2.0 l engine, turbocharger) -oEdition ra
c
08.2014
ss
ce
le
un
pt
an
d
itte
y li
♦ Hot air blower from wiring harness repair set - VAS 1978-
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
♦ Nozzle attachment from wiring harness repair set - VAS 1978-
atio
om
n
c
i
♦ Grip pliers
or
n thi
te
sd
a
Removing:
iv
o
pr
cum
r
fo
en
ng
t.
yi Co
cardiagn.com
op
– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
C py
t. rig
gh
screen wiper system; Removing and installing wiper arms .
ht
pyri by
Vo
o
by c lksw
– Remove plenum chamber cover ⇒ General body repairs, ex‐
cted agen
Prote AG.
terior; Rep. gr. 64 ; Flush-bonded windows; Assembly over‐
view - plenum chamber cover .
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).
– 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.
– Unscrew shear-head bolt -2- using pliers on bolt head.
The procedure for the second shear-head bolt is exactly the
same.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Pull connector -1- off heated windscreen control unit - J505- .
– Lift cover -1- and pull it forwards.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
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cardiagn.com
nl
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itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
– Slide connector locking devices -1- on engine control unit out‐ spec
es, in part or in w
wards and pull off both connectors. t to the co
– Remove retainer frame with engine control unit from plenum

chamber.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
– Press locking device -1- outwards and slide engine control unit
o
m
f
-2- from retaining frame.

en
ng
t.
yi Co
op
Installing:
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Slide engine control unit -1- into retaining frame in direction of

arrow.
– Fit retainer frame with engine control unit onto retainer in ple‐
num chamber.
Specified torque of securing nuts for retainer: 6 Nm.

-1- inwards.
cardiagn.com
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
– Slide cover -1- over engine ise and press it down‐
control hunit
r nte
o eo
wards. s aut ra
c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Tighten new shear-head bolts -2- evenly until bolt head shears
l purpos
off.
– Fit connector -1- to heated windscreen control unit - J505- .
nf
ercia
or

m
m
atio

om

n in
or c
thi
e

t
sd
iva

r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤

gine control unit - J623- (with locking
clip)
Note
DANGER!
cardiagn.com
♦ Grip pliers
– If the engine control unit is to be renewed, connect Vehicle
diagnostic, testing and information system - VAS 5051 B- and
carry out “Renewing engine control unit” in guided functions.
Removing:
– Remove wiper arms ⇒ Electrical system; Rep. .gr.
Volks92
wa;geWind‐
gen AGwiper arms
screen wiper system; Removing andolkinstalling
n AG d
. oes no
swa
V t gu
by ara
– Remove plenum chamber cover ris ⇒ General body repairs, ex‐
ed nte
terior; Rep. gr. 64 ; Flush-bonded
au
tho windows; Assembly over‐ eo
ra
view - plenum chamber cover
ss . c
ce
le
un
pt
an
d
itte
y li
Note
rm
ab
pe
ility
ot
In some vehicles covers are installed to protect the engine control

wit
, is n
unit from water. These are tightened to the engine control unit by
h re
hole
bolts -1-.
spec
es, in part or in w
t to the co
– Remove bolts -1-.

– Remove cover, if fitted.
rrectness of i
– Cover the plenum chamber with a clean cloth so that it is not

l purpos
scratched.
– Raise engine control unit with control unit bracket slightly.
nform
ercia
– Release engine control unit -arrows- and pull out slightly.

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Bend the upper ends -1- of locking clip outwards.

– Remove shear-head bolts -2- using grip pliers and remove
locking clip. agen
AG. Volkswagen AG d
o w es n
olks ot g
byV ua
ed ran
ris tee
tho or
au ac
ss
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le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
– Slide connector locking devices -1- on engine control unit out‐
es, in part or in w
wards and pull off both connectors.
t to the co
– Remove engine control unit.
rrectness of i
Installing:
l purpos
cardiagn.com
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
c
– Slide engine control unit -1- in direction of -arrow- into control
um
fo
unit retainer until it engages.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

-1- inwards.
– Take a new locking clip and tighten new shear-head bolts
evenly until heads shear off.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Tighten control unit bracket and, if fitted, the cover to bracket

with bolts -1-.
Specified torque
Control unit bracket to bracket 6 Nm
swage es n
cardiagn.com
olk ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Seat Manual Leon FR 2008 BWA

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Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤

4-cylinder injection engine (2.0 l engine, turbocharger) - Edition 08.2014

24 – Mixture preparation - injection

Removing and installing fuel rail ⇒ page 283 .

Removing and installing fuel pressure sender - G247-

Checking fuel pressure sender - G247- ⇒ page 290 .

Removing and installing injectors ⇒ page 293 .

Renew Teflon seal on injector ⇒ page 294

1.1 General notes on injection

♦ Fuel hoses in engine compartment must be secured only with

spring-type clips which conform to production standard. The

♦ The battery must be disconnected only with ignition switched

off. If a coded radio is installed, ascertain code before discon‐

♦ Observe required procedures after connecting battery ⇒ Elec‐

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

1. Injection system 269

iness code must be generated ⇒ Vehicle diagnostic tester

1.2 Technical data

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

270 Rep. gr.24 - Mixture preparation - injection

❑ Observe fitting marks

1.4 Removing and installing engine cover/

1. Injection system 271

– Remove intake air duct -arrow-.

– Remove all bolts -arrows-.

– Open engine cover (note retainers -arrows-).

272 Rep. gr.24 - Mixture preparation - injection

– Pull air filter element out of engine cover.

♦ Always use genuine part for air filter element.

– Check air mass meter - G70- and intake air duct

1. Injection system 273

❑ Removing and installing

10 - To activated charcoal filter

❑ Check ⇒ page 297 .

15 - Intake manifold support

18 - Bonded rubber mounting

19 - Throttle valve module - J338-

274 Rep. gr.24 - Mixture preparation - injection

1.7 Removing and installing intake manifold

♦ Assembly overview - intake manifold ⇒ page 273 .

– Remove throttle valve module - J338- ⇒ page 284 .

– Disconnect vacuum hose between intake manifold and vac‐

uum pump at intake manifold.

Engine code BPY:

1. Injection system 275

Engine codes AXX, BWA

– Disconnect breather line -2-.

The fuel system is pressurised!

♦ Wear eye protection and protective clothing to avoid pos‐

♦ Before loosening line connections, wrap a cloth around

the connection. Then release pressure by carefully pulling

– Unscrew banjo bolt -2-, at the same time counterhold connec‐

276 Rep. gr.24 - Mixture preparation - injection

Vehicles from 05.2006:

Installation is carried out in the reverse order. When installing,

note the following:

manifold was removed, renew the Teflon seal of the injector

If the intake manifold flap motor - V157- or the intake manifold

1. Injection system 277

1.8 Removing and installing intake manifold

♦ Commercially available 1/4" drive ratchet handle e.g.. Hazet

♦ T30 bit insert

– Remove engine cover/air filter ⇒ page 271 .