Volkswagen Passat B6 2005 - >

(B6)

Fuel injection system

General notes on fuel injection 24-1, General notes on
fuel injection

Safety precautions 20-1, Safety precautions

Rules of cleanliness 24-1, Rules for cleanliness

Technical data 24-1, Technical data

Intake manifold, assembly overview 24-1, Intake

manifold, assembly overview

Fuel rail, assembly overview 24-1, Fuel rail, assembly

overview

Air filter, assembly overview 24-1, Engine cover/air filter,

assembly overview

Intake manifold, removing and installing 24-1, Intake

manifold, removing and installing

Fuel injectors, removing and installing 24-1, Fuel

injectors, removing and installing

Replace Teflon sealing ring on fuel injector 24-1, Teflon

sealing ring on fuel injector, replacing

General notes on fuel injection

„ Fuel hoses in engine compartment may only be

secured with spring-type clamps appropriate for the
model type. The use of clamp or screw type clips is
not permissible.

„ Ignition must be switched off when disconnecting the

battery. Obtain radio code for radios with anti-theft
coding before disconnecting battery.

„ Observe safety precautions after connecting battery

Repair Manual, Electrical Equipment, Repair Group 27,

Disconnecting and connecting battery

„ For trouble-free operation of the electrical

Fuel injection system Стр. 2 из 24

components a voltage of at least 11.5 V is

necessary.

„ Do not use sealants containing silicone. Particles of

silicone drawn into engine, will not be burnt in the
engine and damage the oxygen sensor.

„ If engine only starts briefly and then turns off again

after troubleshooting, repair or checking of
components, it may be that the immobilizer is
blocking the Engine Control Module (ECM). Control
module must then be adapted if necessary.

„ To conclude work, check DTC memory of Engine

Control Module (ECM), erase all DTC entries which
may have occurred during the tests and repairs. If
DTC memory was erased, generate readiness code
Vehicle Diagnosis, Testing and Information
System VAS 5051 "Guided Function" .

„ Vehicles with an airbag are equipped with a crash

fuel shut-off system. It reduces the danger of a fire in
a crash as the fuel pump is switched off via fuel
pump relay.

„ When opening the driver door, the fuel pump is

activated for 2 seconds to build pressure in the fuel
system. This improves comfort of engine start-up
behavior.

Safety precautions 20-1, Safety precautions

Rules of cleanliness 24-1, Rules for cleanliness

Technical data 24-1, Technical data

Rules for cleanliness

When working on the fuel supply/injection system, pay

careful attention to the following "5 rules" :

„ Thoroughly clean all connections and the

surrounding area before disconnecting.

„ Place parts that have been removed on a clean

surface and cover them. Do not use fluffy cloths!
Fuel injection system Стр. 3 из 24

„ Carefully cover over opened components or seal, if

repairs are not performed immediately.

„ Only install clean components: Only unpack

replacement parts immediately prior to installation.
Do not use parts that have been stored loose (e.g. in
tool boxes etc.).

„ When the system is open: Avoid working with

compressed air if possible. Do not move vehicle
unless absolutely necessary.

Technical data

Engine code BPY

Idle test
Engine idle speed 1) RPM 620 to 800
Engine control module
System designation Motronic MED 9.1
Replacement part number ETKA (electronic parts catalog)
Engine speed (RPM) limitation RPM approx. 6800
Fuel pressure
Low pressure bar approx. 4.0 to 6.0
High pressure bar approx. 40 to 120

1) If
voltage supply of Engine Control Module (ECM) drops
below 12 volts, idle speed is raised in stages up to 990
RPM. Idle speed is not adjustable.

Intake manifold, assembly overview

Fuel injection system Стр. 4 из 24

„ 10 Nm

„ Retaining clip

„ 3 Nm

„ Stud bolt, 10 Nm

„ Gasket

„ Replace

„ Intake manifold

„ With intake manifold flaps

„ Coupling rod

„ Intake Flap Motor V157 with

Intake Manifold Runner Position
Sensor G336
Fuel injection system Стр. 5 из 24

„ 7 Nm

„ To EVAP canister

„ Hose

„ Evaporative Emission (EVAP)

Canister Purge Regulator Valve
N80

„ Hose

„ Double check valve

„ Checking 24-2,
Components, checking

„ Intake manifold support

„ 25 Nm

„ 10 Nm

„ Bonded rubber bushing

„ Throttle valve control module

J338

„ With Throttle Drive (for

Electronic Power Control
(EPC)) G186 , Throttle Drive
Angle Sensor 1 (for
Electronic Power Control
(EPC)) G187 and Throttle
Drive Angle Sensor 2 (for
Electronic Power Control
(EPC)) G188

„ Removing and installing

24-1, Throttle Valve Control
Module J338 , removing and
installing

„ 7 Nm

„ Seal

„ Replace if damaged

„ 5 Nm

„ Intake Air Temperature (IAT)

Sensor G42
Fuel injection system Стр. 6 из 24

„ 10 Nm

Fuel rail, assembly overview

Warning!

Follow safety measures for releasing fuel pressure in

high pressure area 20-1, Releasing fuel pressure in
high pressure area

„ Cylinder 1 Fuel Injector N30 to

Cylinder 4 Fuel Injector N33

„ Removing and installing

24-1, Fuel injectors,
removing and installing

„ 5 Nm

„ Fuel rail

„ Plate nut

„ Pressure relief valve

„ 30 Nm
Fuel injection system Стр. 7 из 24

„ To remove and install,

remove intake manifold
24-1, Intake manifold,
removing and installing

„ Fuel line

„ Do not install when under

tension

„ Tighten union nut to 20 Nm

„ Bracket

„ Fuel line

„ Do not install when under

tension

„ Tighten union nut on fuel rail

to 25 Nm.

„ Connector

„ For fuel injectors

„ 7 Nm

„ Fuel Pressure Sensor G247

„ 20 Nm

„ Removing and installing

24-1, Fuel Pressure Sensor
G247 , removing and
installing

Engine cover/air filter, assembly overview

Fuel injection system Стр. 8 из 24
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„ Mass air flow (MAF) sensor G70

„ 3 Nm

„ Upper section of air filter/engine

cover

„ Spring-type clip

„ Intake air guide

„ Filter element

„ Air filter lower part

„ 3 Nm

„ Heat shield

„ Rubber boot

„ Note installation marking

Fuel injection system Стр. 9 из 24

„ Intake tube

„ Note installation marking

Engine cover/air filter, removing and installing

- Disconnect intake duct - 1 - .

- Disconnect connector - 2 - .

- Remove bolts - 3 - .

- Remove engine cover upward in sequence - A to D - at

places shown.

Installing

- Ensure rubber bearings - arrows - are inserted in engine

cover.

- Position engine cover in installation position and press

rubber bearings onto anchor screws at the same time.

Installation is performed in reverse order of removal.

Air filter element, removing and installing

Fuel injection system Стр. 10 из 24

Removing

- Remove engine cover/air filter 24-1, Engine cover/air

filter, removing and installing .

- Remove intake air guide - arrow - .

- Remove all screws - arrows - .

- Separate engine cover, paying attention to retainers -

arrows - .
Fuel injection system Стр. 11 из 24

- Pull air filter element out of engine cover.

Air filter insert, installing

Note:

„ Always use an original equipment air filter element.

„ Air filter housing must be clean.

„ Note the following when blowing out the air filter

housing with pressurized air: To avoid malfunctions,
cover Mass Air Flow (MAF) Sensor G70 with a clean
cloth.

- Check Mass Air Flow (MAF) Sensor G70 and intake duct
Item - 5 - for salt residue, dirt and leaves.

- Ensure air filter element is properly centered when

placed into the mounting of the lower part of air filter
housing.

- Set upper part of air filter housing onto lower part of air
filter housing, without using much force. When doing this,
make sure that the upper part of air filter housing is not
placed crooked onto air filter element (observe sealing lip
of air filter element).

Installation is in reverse order or removal.

Throttle Valve Control Module J338 , removing and

installing

Removing

- Remove engine cover/air filter 24-1, Engine cover/air

filter, removing and installing .

- Remove insulation pan

Fuel injection system Стр. 12 из 24

Repair Manual, Body Exterior, Repair Group 50, Front

body; assembly overview of noise insulation

- Loosen bolts and clamps - arrows - and remove charge

air pipe and hose downward.

- Remove four bolts on Throttle Valve Control Module

J338 and remove it.

Installing

Installation is in reverse order of removal. Note the

following:

- If a new Throttle Valve Control Module J338 was

installed, adapt engine control module do it Vehicle
Diagnosis, Testing and Information System VAS 5051
"Guided Functions" .

Intake manifold, removing and installing

Warning!

Follow safety measures for releasing fuel pressure in

high pressure area 20-1, Releasing fuel pressure in
high pressure area

Removing

Note:

„ Observe safety precautions 20-1, Safety

Fuel injection system Стр. 13 из 24

precautions

„ Observe rules for cleanliness 24-1, Rules for

cleanliness

„ If a fuel injector was pulled out of cylinder head

when removing the intake manifold, the Teflon
sealing ring must be replaced 24-1, Teflon sealing
ring on fuel injector, replacing

„ Intake manifold, assembly overview 24-1, Intake

manifold, assembly overview

- Remove Throttle Valve Control Module J338 24-1,

Throttle Valve Control Module J338 , removing and
installing .

- Disconnect all electrical harness connectors necessary.

- Disconnect vacuum hose between intake manifold and

vacuum pump from intake manifold.

Warning!

„ For reasons of safety, remove Fuse 34 (on fuse

panel D) SD34 for Fuel Pump (FP) from fuse
holder in instrument panel on right side before
opening the fuel supply system, as the FP may
be activated by the drivers door contact switch.

„ Fuel supply line is under pressure! Wear

protective goggles and protective clothing to
prevent injuries and contact with skin. Before
removing from hose connection wrap a cloth
around the connection. Then release pressure by
carefully pulling hose off connection.
Fuel injection system Стр. 14 из 24

- Disconnect vacuum line - 1 - ventilation line - 2 - and

fuel line - 3 - . To do so, press release buttons.

Disconnect vacuum lines - arrows - from intake manifold

and from cylinder head cover.

- Disconnect both fuel lines from high pressure pump.

- Remove coolant pipe and oil dipstick guide from intake

manifold - arrows - and pull off oil dipstick guide upward
from engine.
Fuel injection system Стр. 15 из 24

- Remove intake manifold support - arrows - and

disconnect connector - 1 - from Fuel Pressure Sensor
G247 .

- Remove all bolts from intake manifold.

- Carefully pull off intake manifold with fuel rail from

cylinder head.

Installing

Installation is in reverse order of removal. Note the

following:

If a fuel injector was pulled out of cylinder head when

removing the intake manifold, replace Teflon sealing ring of
fuel injector 24-1, Teflon sealing ring on fuel injector,
replacing .

Replace O-rings between fuel injectors and fuel rail and

coat them lightly with clean motor oil.

Position intake manifold with fuel rail on cylinder head and

press evenly onto fuel injectors.

If Intake Flap Motor V157 or intake manifold was replaced,

Intake Manifold Runner Position Sensor G336 must be
adapted to ECM Vehicle Diagnosis, Testing and
Information System VAS 5051 "Guided Functions" .

Torque specifications Nm
Mounting bolts for intake manifold 10
Bolt for intake manifold support 23
Nut for intake manifold support 10
Fuel supply line to high pressure pump 25
Fuel return line to high pressure pump (replace banjo fitting) 17
Bolts for Intake Flap Motor V157 7
Fuel injection system Стр. 16 из 24

Fuel rail, removing and installing

- Remove intake manifold 24-1, Intake manifold,

removing and installing .

- Remove hoses from EVAP canister.

- To do so, open hose clamp - 1 - .

- Loosen two fuel rail bolts - arrows - .

- Remove hose connection - 1 - from intake manifold and

loosen both bolts - arrows - .

- Loosen union nuts of both fuel lines - 2 and 3 - .

- Carefully pry off linkage from Intake Flap Motor V157 - 4

- .

- Remove Intake Flap Motor V157 - 5 - .

Fuel injection system Стр. 17 из 24

- Remove fuel rail from intake manifold.

- Installation is in reverse order of removal.

Tightening torques 24-1, Fuel rail, assembly overview

Fuel Pressure Sensor G247 , removing and installing

Special tools, testers and auxiliary items required

„ Assembly tool T10118

„ Socket wrench insert 27 mm VAS 5301/7

Warning!

Follow safety measures for releasing fuel pressure in

high pressure area 20-1, Releasing fuel pressure in
high pressure area

Removing:
Fuel injection system Стр. 18 из 24

- Disconnect coolant pipe and oil dipstick guide from intake

manifold - arrows - and pull off oil dipstick guide upward
from engine.

- Disengage connector from Fuel Pressure Sensor G247

using assembly tool T10118 .

- Remove Fuel Pressure Sensor G247 using socket

wrench insert 27 mm VAS 5301/7 .

Installing:

Installation is in reverse order of removal. Note the

following:

Tightening torque 24-1, Fuel rail, assembly overview

Fuel injectors, removing and installing

Special tools, testers and auxiliary items required

„ Tool set T10133

Fuel injection system Стр. 19 из 24

Fuel injector, individual parts

„ Radial compensation (replace)

„ Combustion chamber sealing ring (Teflon sealing
ring), replace, the ring must not be greased or
handled with any other lubricants when installing.
„ Groove on fuel injector
„ Support washer (replace)
„ O-ring (replace, coat lightly with clean engine oil
when installing)
„ Support ring

Removing:

- Remove intake manifold 24-1, Intake manifold,

removing and installing .

- Seal intake channels with a clean cloth.

- Bend retaining tabs of radial compensation to the side

using a screwdriver and pull off support ring from fuel
injector.

Note:

„ Radial compensation retaining tabs are destroyed by

this (retaining tabs break). If fuel injector is re-
Fuel injection system Стр. 20 из 24

installed, radial compensation must be replaced.

- Screw hammer T10133/3 to puller T10133/2 . Then

guide puller T10133/2 into groove on fuel injector and
carefully tap fuel injector out.

Installing:

Note:

„ The Teflon sealing ring of fuel injector may not be

oiled or greased.

„ Possibly an opened intake valve hinders the

cleaning. In this case, engine must be turned further
by hand using a socket wrench on the crankshaft.

- Thoroughly clean bores for high pressure fuel injectors in

cylinder head using nylon brush T10133/4 .

- Replace O-ring and Teflon sealing ring of fuel injector

24-1, Teflon sealing ring on fuel injector, replacing .
Fuel injection system Стр. 21 из 24

- Using assembly drift T10133/9 , press fuel injector into

hole in cylinder head until it stops.

- Make sure fuel injectors are positioned correctly in

cylinder head.

Teflon sealing ring on fuel injector, replacing

Special tools, testers and auxiliary items required

„ Tool set T10133

Note:

„ Teflon sealing ring must not be oiled.

Fuel injection system Стр. 22 из 24

- Clean fuel injector in area of sealing ring - arrow - .

Remove any deposits (coking) using a brass brush.

- Carefully cut sealing ring using a knife.

- Clean sealing ring groove.

- Insert a new sealing ring on to assembly cone

T10133/5 . Slide sealing ring as far as it will go on to
assembly cone T10133/5 using assembly sleeve
T10133/6 .

- Rotate assembly sleeve T10133/6 and slide sealing ring

on to assembly cone T10133/5 up to end.
Fuel injection system Стр. 23 из 24

- Place assembly cone T10133/5 on to fuel injector and

slide sealing ring on to fuel injector using assembly sleeve
T10133/6 .

- Remove assembly cone T10133/5 and slide sealing ring

into groove using assembly sleeve T10133/6 .

- Press calibrating sleeve T10133/7 using a gentle turning

motion (approx. 180 ) on to fuel injector until it stops.

- Pull off calibrating sleeve T10133/7 again using turning

motion in opposite direction.

- Press calibrating sleeve T10133/8 using a gentle turning

motion (approx. 180 ) on to fuel injector until it stops.
Fuel injection system Стр. 24 из 24

- Pull off calibrating T10133/8 again using turning motion

in opposite direction.

- Replace O-ring on fuel injector and support washer.

- Install fuel injector again with support ring - 1 - and clip

in radial compensation - 2 - on support ring.
Components, checking Стр. 1 из 2

24 - 2

Components, checking
Checking double check-valve

Special tools, testers and auxiliary items required

„ Hand vacuum pump VAS 6213

- Disconnect connectors from Evaporative Emission

(EVAP) Canister Purge Regulator Valve N80 and Low Fuel
Pressure Sensor G410 - arrows - .

- Disconnect Evaporative Emission (EVAP) Canister Purge

Regulator Valve N80 - B - from hose - A - .
Components, checking Стр. 2 из 2

- Set slide ring - 1 - on hand vacuum pump VAS 6213 to

position - A - for "vacuum" .

- Connect hand vacuum pump VAS 6213 on hose to

double check-valve - arrow - .

- Operate hand vacuum pump VAS 6213 several times,

vacuum must build up.

If no vacuum builds up, replace double check-valve.

Engine control module (ECM) Стр. 1 из 8

24 - 3

Engine control module (ECM)

Removing and installing Engine Control Module (ECM)
24-3, Engine Control Module (ECM), removing and
installing

Engine Control Module (ECM) secured with anti-theft

immobilizer, removing and installing 24-3, Engine
Control Module (ECM) secured with anti-theft immobilizer,
removing and installing

Engine Control Module (ECM), removing and installing

Note:

„ If it is desired to replace Engine Control Module

(ECM), connect Vehicle Diagnosis, Testing and
Information System VAS 5051 and perform guided
function "Replace Engine Control Module (ECM)" .

Caution!

On vehicles with heavy duty suspension, vehicle must

be limited to a maximum speed of 210 km/h with the
engine control module. At speeds above 210 km/h,
damage to input shafts can occur. Perform Guided
Function "Limit Maximum Speed" using the Vehicle
Diagnostic, Testing and Information System VAS
5051B .

Removing

- Switch off ignition.

- Remove windshield wiper arms and plenum chamber

cover

Repair Manual, Electrical Equipment, Repair Group 92,

- Disconnect harness connector - 1 - from Heated

Windshield Control Module J505 .
Engine control module (ECM) Стр. 2 из 8
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- Slide connector release catches - 2 - on Engine Control

Module (ECM) outward and disconnect both harness
connectors.

- Remove mounting bolts - 3 - .

- Remove mounting frame with Engine Control Module

(ECM) from plenum chamber.

- Press release catches - 1 - outward and slide Engine

Control Module (ECM) - 2 - from mounting frame.

Installing

- Slide Engine Control Module (ECM) - 1 - into mounting

frame in direction of - arrow - .
Engine control module (ECM) Стр. 3 из 8

- Place mounting frame with Engine Control Module (ECM)

on to bracket - 4 - .

Tightening torque of mounting nuts for bracket: 6 Nm.

- Tighten mounting bolts - 3 - to 7 Nm.

- Connect harness connectors to Engine Control Module

(ECM) and slide release catches - 2 - inward.

- Connect harness connector - 1 - to Heated Windshield

Control Module J505 .

- Install plenum chamber cover

Repair Manual, Body Exterior, Repair Group 64,

Removing and installing plenum chamber cover

- Install windshield wiper arms

Repair Manual, Electrical Equipment, Repair Group 92,

Front windshield wiper system; removing and installing
wiper arms

Engine Control Module (ECM) secured with anti-theft

immobilizer, removing and installing

Note:

„ If it is desired to replace Engine Control Module

(ECM), connect Vehicle Diagnosis, Testing and
Information System VAS 5051B and perform guided
function "Replace Engine Control Module (ECM)" .
Engine control module (ECM) Стр. 4 из 8

Caution!

On vehicles with heavy duty suspension, vehicle must

be limited to a maximum speed of 210 km/h with the
engine control module. At speeds above 210 km/h,
damage to input shafts can occur. Perform Guided
Function "Limit Maximum Speed" using the Vehicle
Diagnostic, Testing and Information System VAS
5051 .

Special tools, testers and auxiliary items required

„ Hot air gun from wiring harness repair kit VAS

1978

„ Attachment nozzle from wiring harness repair kit

VAS 1978

Removing

- Switch off ignition.

- Remove windshield wiper arms

Repair Manual, Electrical Equipment, Repair Group 92,

Front windshield wiper system; removing and installing
wiper arms

- Remove plenum chamber cover

Repair Manual, Body Exterior, Repair Group 64,

Removing and installing plenum chamber cover

.
Engine control module (ECM) Стр. 5 из 8

Note:

„ Thread of shear bolts is equipped with locking

compound. By heating the shear bolts using a hot air
gun, inhibition effect of the locking compound is
lowered.

Caution!

Cover wires, harness connectors and control modules

in the close vicinity of Engine Control Module (ECM) to
prevent damage from burning.

Perform adjustments on hot air gun - 4 - as shown:

- Turn potentiometer for temperature adjustment - 2 - to

maximum heat output (600 C).

- Move two stage switch for air quantity - 3 - to position 3.

Warning!

By heating the shear bolts, parts of the protective

housing are heated intensely. Wear protective gloves
to prevent injuries.

- Guide nozzle of hot air gun on to shear bolts.

- Switch hot air gun on and warm bolts.

- Remove shear bolt - 2 - using pliers on bolt head.

The procedure for the second shear bolt is exactly the

same.
Engine control module (ECM) Стр. 6 из 8

- Disconnect harness connector - 1 - from Heated

Windshield Control Module J505 .

- Lift cover - 1 - and pull it forward.

- Slide connector release catches - 1 - on Engine Control

Module (ECM) outward and disconnect both harness
connectors.

- Remove mounting frame with Engine Control Module

(ECM) from plenum chamber.
Engine control module (ECM) Стр. 7 из 8

- Press release catches - 1 - outward and slide Engine

Control Module (ECM) - 2 - from mounting frame.

Installing

- Slide Engine Control Module (ECM) - 1 - into mounting

frame in direction of - arrow - .

- Place mounting frame with Engine Control Module (ECM)

on to bracket in plenum chamber.

Tightening torque of mounting nuts for bracket: 6 Nm.

- Connect harness connectors to Engine Control Module

(ECM) and slide release catches - 1 - inward.
Engine control module (ECM) Стр. 8 из 8

- Slide cover - 1 - over Engine Control Module (ECM) and

press it downward.

- Tighten new shear bolts - 2 - uniformly until bolt heads

shear off.

- Connect harness connector - 1 - to Heated Windshield

Control Module J505 .

- Install plenum chamber cover

Repair Manual, Body Exterior, Repair Group 64,

Removing and installing plenum chamber cover

- Install windshield wiper arms

Repair Manual, Electrical Equipment, Repair Group 92,

Front windshield wiper system; removing and installing
wiper arms