2.0L 4-CYL 4V TURBO FUEL INJECTION IGNITION, ENGINE CODE(S): BPG, BWT

• HEADINGS
  • 24 - Multiport Fuel Injection (MFI)
    • Safety measures and cleanliness rules
      • General information, On Board Diagnostic (OBD)
      • Safety precautions
      • Cleanliness rules and instructions for working on fuel system
    • Procedure that must be performed before opening the high-pressure fuel injection system - Pay close attention!
    • Technical data
    • Overview of component locations
      • Fuel Pressure Sensor G247 - 1 - (Torque Specification 22 Nm)
      • Camshaft Position (CMP) Sensor G40 - 1 -
      • Mass Air Flow (MAF) Sensor G70 - 1 -
      • Camshaft Adjustment Valve 1 N205 - 1 - and Fuel Pressure Regulator Valve N276 - 2 -
      • Intake Air Temperature (IAT) Sensor G42 - 1 - Throttle Valve Control Module J338 - 2 -
      • Fuel Pump (FP) Control Module J538 - 1 -
      • Electrical harness connectors
      • Oxygen sensors
      • Installed location of Engine Control Module (ECM) J623
      • Engine Coolant Temperature (ECT) Sensor G62 - 1 -
      • Installed location Brake Light Switch F/Brake Pedal Switch F47 , Clutch Pedal Switch F36
      • Installed location in 4-socket relay carrier, plenum chamber E-box
      • Installed location on 9-socket relay carrier in driver footwell
      • Electrical harness connectors
      • Component locations beneath intake manifold
      • Charge Air Pressure Sensor G31 - 1 -
      • Oil Level Thermal Sensor G266
      • Components on turbocharger
    • Air filter, assembly overview
    • Engine cover, removing and installing
    • Air filter insert, removing and installing
    • Mass Air Flow (MAF) Sensor G70 , removing and installing
    • Intake Manifold, assembly overview
    • Fuel rail, assembly overview
    • Intake manifold with fuel rail, removing and installing
    • Fuel rail, removing and installing
    • Fuel injectors, removing and installing
    • Combustion chamber sealing ring (Teflon sealing ring), replacing
    • Fuel pressure and residual pressure before high pressure pump, checking
    • High pressure pump, assembly overview
    • High pressure pump, removing and installing
    • Wiring and components, checking with Test box V.A.G 1598/42
    • Engine Control Module (ECM) J623 , replacing
    • Heated Oxygen Sensor (HO2S) G39 and Oxygen Sensor (O2S) Heater Z19 before catalytic converter, removing and installing
    • Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 and Oxygen Sensor (O2S) Heater 1 (behind Three Way Catalytic Converter (TWC)) Z29 , removing and installing
  • 28 - Ignition/Glow plug System
    • Ignition system, checking
      • Ignition system, general information
      • Safety precautions
      • Technical data, Ignition
      • Ignition system, assembly overview
      • Ignition coils with power output stage, removing and installing
• FIGURES
  • Fig. 1: Identifying Main Fuse Panel
  • Fig. 2: Identifying Main Fuse Panel
  • Fig. 3: Identifying Assembly Tool T10118
  • Fig. 4: Removing Electrical Connector From Fuel Pressure Regulator Valve N276 Using Assembly Tool T10118
  • Fig. 5: Overview Of Component Locations
  • Fig. 6: Fuel Pressure Sensor G247
  • Fig. 7: Camshaft Position (CMP) Sensor G40
  • Fig. 8: Mass Air Flow (MAF) Sensor G70
  • Fig. 9: Camshaft Adjustment Valve 1 N205 And Fuel Pressure Regulator Valve N276
  • Fig. 10: Intake Air Temperature (IAT) Sensor G42 Throttle Valve Control Module J338
  • Fig. 11: Fuel Pump (FP) Control Module J538
  • Fig. 12: Disconnecting 4-Pin Electrical Harness Connector From Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130
  • Fig. 13: Identifying Oxygen Sensors
  • Fig. 14: Installed Location Of Engine Control Module (ECM) J623
  • Fig. 15: Engine Coolant Temperature (ECT) Sensor G62
  • Fig. 16: Installed Location Brake Light Switch F/Brake Pedal Switch F47 , Clutch Pedal Switch F36
  • Fig. 17: Installed Location In 4-Socket Relay Carrier, Plenum Chamber E-Box
  • Fig. 18: Installed Location On 9-Socket Relay Carrier In Driver Footwell
  • Fig. 19: Electrical Harness Connectors
  • Fig. 20: Component Locations Beneath Intake Manifold
  • Fig. 21: Charge Air Pressure Sensor G31
  • Fig. 22: Oil Level Thermal Sensor G266
  • Fig. 23: Components On Turbocharger
  • Fig. 24: Installation Position Of Turbocharger Recirculating Valve N249
  • Fig. 25: Air Filter, Assembly Overview
  • Fig. 26: Removing Engine Cover
  • Fig. 27: Disconnecting Electrical Harness Connector From Mass Air Flow (MAF) Sensor G70
  • Fig. 28: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
  • Fig. 29: Identifying Upper Part Of Air Filter Bolts
  • Fig. 30: Disconnecting Electrical Harness Connector From Mass Air Flow (MAF) Sensor G70
  • Fig. 31: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
  • Fig. 32: Intake Manifold, Assembly Overview
  • Fig. 33: Fuel Rail, Assembly Overview
  • Fig. 34: Disconnecting Fuel Line
  • Fig. 35: Removing Both Bolts From Valve Cover/Coolant Pipe
  • Fig. 36: Removing Both Bolts From Valve Cover/Coolant Pipe
  • Fig. 37: Removing Bolt From Oil Line And From Coolant Pipe
  • Fig. 38: Identifying High Pressure Pump Fuel Lines
  • Fig. 39: Identifying 3-Pin Connector From Fuel Pressure Sensor -G247-
  • Fig. 40: Identifying 3-Pin Connector From Fuel Pressure Sensor -G247-
  • Fig. 41: Removing Bolt For Oil Line
  • Fig. 42: Removing Nut From Intake Manifold Support
  • Fig. 43: Separating Oil Dipstick Guide Tube At Separation Point And Removing Bolt For Intake Manifold Bracket
  • Fig. 44: Identifying Hose Clamp & Bolts
  • Fig. 45: Removing/Installing Coupling Rod From Intake Flap Motor V157
  • Fig. 46: Removing/Installing Coupling Rod From Intake Flap Motor V157
  • Fig. 47: Removing Fuel Rail From Intake Manifold
  • Fig. 48: Identifying Tool Set T10133
  • Fig. 49: Identifying Fuel Injector, Individual Parts
  • Fig. 50: Identifying Fuel Injector, Individual Parts
  • Fig. 51: Bending Retaining Tabs Of Radial Compensation To Side
  • Fig. 52: Installing Hammer T10133/3 To Puller T10133/2
  • Fig. 53: Identifying Fuel Injector, Individual Parts
  • Fig. 54: Placing Assembly Cone T10133/5 With New Teflon Seal Onto Fuel Injector
  • Fig. 55: Pushing Teflon Seal Further Onto Assembly Cone T10133/5
  • Fig. 56: Pushing Calibration Sleeve T10133/7 Over Fuel Injector Up To Stop
  • Fig. 57: Pushing Calibration Sleeve T10133/8 Over Fuel Injector Up To Stop
  • Fig. 58: Cleaning Bores For High Pressure Fuel Injectors In Cylinder Head Using Nylon Brush T10133/4
  • Fig. 59: Installing Fuel Injector Again With Support Ring And Clipping In Radial Compensation On Support Ring
  • Fig. 60: Using Assembly Drift T10133/9 To Press Fuel Injector Into Hole In Cylinder Head Until It Stops
  • Fig. 61: Identifying Pressure Gauge V.A.G 1318
  • Fig. 62: Identifying Remote Control Connection V.A.G 1348/3A
  • Fig. 63: Identifying Main Fuse Panel
  • Fig. 64: Identifying Fuel Pump (FP) Control Module J538 Electrical Harness Connector
  • Fig. 65: Unbolting Cover For Locking Flange In Luggage Compartment
  • Fig. 66: Disconnecting Electrical Harness Connector At Locking Flange
  • Fig. 67: Connecting Other End Of Hand Held Remote Starter (Jumper) To Vehicle Battery (+)
  • Fig. 68: Removing Engine Cover
  • Fig. 69: Disconnecting Fuel Line
  • Fig. 70: Connecting Pressure Gauge V.A.G 1318 To Fuel Supply Line Using Adapters V.A.G 1318/11 And V.A.G 1318/12
  • Fig. 71: Locating V.A.G 1318 Shut-Off Tap
  • Fig. 72: Connecting Pressure Gauge V.A.G 1318 To Fuel Supply Line Using Adapters V.A.G 1318/11 And V.A.G 1318/12
  • Fig. 73: High Pressure Pump, Assembly Overview
  • Fig. 74: Identifying Bolts, 3-Pin Connector, Low Fuel Pressure Sensor -G410-, 2-Pin Connector And Fuel Pressure Regulator Valve -N276-
  • Fig. 75: Connecting Test Box V.A.G 1598/42 To Wiring Harness With Adapter Cable V.A.G 1598/39-1 Or Adapter Cable V.A.G 1598/39-2
  • Fig. 76: Connecting Test Box V.A.G 1598/42 To Wiring Harness With Adapter Cable V.A.G 1598/39-1 Or Adapter Cable V.A.G 1598/39-2
  • Fig. 77: VAS 5051 Tester Displaying Control Module Identification And Coding
  • Fig. 78: Identifying Plenum Chamber Cover & Removing Rubber Seal
  • Fig. 79: Removing Securing Clips And Cowl
  • Fig. 80: Removing Securing Clips And Cowl
  • Fig. 81: Removing Screws And Cover From E-Box In Plenum Chamber
  • Fig. 82: Using Screwdriver To Remove Retainer Bar And Engine Control Module (ECM) J623
  • Fig. 83: Removing Protective Housing From Engine Control Module (ECM) J623
  • Fig. 84: Heat Gun, Adapter Nozzle And Pliers
  • Fig. 85: Removing Protective Housing From Engine Control Module (ECM) J623
  • Fig. 86: Removing Protective Housing From Engine Control Module (ECM) J623
  • Fig. 87: Performing Adjustments On Hot Air Gun
  • Fig. 88: Using Heat Gun To Direct Heat Gun Nozzle At Shear Bolt Of Retaining Tab
  • Fig. 89: Using Locking Pliers To Remove Shear Bolt
  • Fig. 90: Disengaging Electrical Connector Retainers And Disconnecting Electrical Connectors From Engine Control Module (ECM) J623
  • Fig. 91: Identifying Ring Spanner 7-Piece Set 3337
  • Fig. 92: Disconnecting 4-Pin Electrical Harness Connector From Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130
  • Fig. 93: Identifying Oxygen Sensors
  • Fig. 94: Identifying Ring Spanner 7-Piece Set 3337
  • Fig. 95: Disconnecting 4-Pin Electrical Harness Connector From Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130
  • Fig. 96: Identifying Oxygen Sensors
  • Fig. 97: Ignition System, Assembly Overview
  • Fig. 98: Identifying Ignition Coil Puller T40039
  • Fig. 99: Removing Ignition Coils With Power Output Stage N70, N127, N291, N292 Electrical Harness Screws
  • Fig. 100: Pulling All Ignition Coils Using Ignition Coil Puller T40039
  • Fig. 101: Removing Ignition Coils With Power Output Stage N70, N127, N291, N292 Electrical Harness Screws
  • Fig. 102: Connecting Connectors To Ignition Coils
• TABLES

ENGINE PERFORMANCE

2.0 Liter 4-Cyl. 4V Turbo Fuel Injection Ignition, Engine Code(s): BPG, BWT

24 - Multiport Fuel Injection (MFI)

Safety measures and cleanliness rules

General information, On Board Diagnostic (OBD)

• The engine control module is equipped with On Board Diagnostics (OBD). Before repairs such as fault finding, check the DTC memory first. Also the vacuum hoses and connections must be checked (unmetered air).
• Fuel hoses in engine compartment must only be secured with spring-type clips. The use of clamp or screw type clips is not permissible.
• For the electric components to work properly, a voltage of at least 11.5 Volts is required.
• Do not use sealants containing silicone. Particles of silicone drawn into the engine, will not be burnt in the engine and damage the oxygen sensor.

• The vehicles have 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.
• At the same time, with this set-up, an improvement in driveability is also attained. When the driver-side door is opened, the Fuel Pump (FP) is activated for 2 seconds so that pressure builds in the fuel system, observe safety measures --> Safety precautions.

Safety precautions

CAUTION:

Fuel system is under pressure! Fuel pressure must be reduced to a residual pressure before opening high pressure area of injection system, see --> Procedure that must be performed before opening the high-pressure fuel injection system - Pay close attention!. After reducing high pressure, connection should be opened immediately. To do this, place a cloth around the connection to reduce residual pressure (approx. 7 bar).

Observe the following if test and measuring instruments are required during a test drive:

CAUTION:

Test and measuring equipment must always be secured to the rear seat and be operated from there by a second person. If test and measuring instruments are operated from the front passengers seat and the vehicle is involved in an accident, there is a possibility that the person sitting in this seat may receive serious injuries when the airbag is triggered.

To reduce the risk of personal injury and/or damage to the fuel injection and ignition system, always observe the following:

• The battery must be disconnected before opening the fuel system, for safety reasons. The fuel pump may be activated by the drivers door contact switch.
• Individuals with a pacemaker must not stay in the danger area of high voltage systems, e.g. ignition systems, xenon light.
• Fuel lines must not be opened when engine is running.
• Only disconnect and reconnect wires for injection and ignition system, including test leads, when ignition is switched off.
• If engine is to be cranked at starting RPM without starting (e.g. for compression testing), disconnect connectors from ignition coils and remove fuse for electric fuel pump.
• It is possible that the control module will recognize a malfunction and store a DTC during some tests. Therefore after completing all checks and repairs the DTC memory must be checked and if necessary erased.
• If the DTC memory was erased, the readiness code must be newly generated.
• Cleaning the engine should only be performed with ignition switched off.
• The battery must only be disconnected and connected with the ignition switched off, since the Engine Control Module (ECM) can otherwise be damaged.

Fig. 1: Identifying Main Fuse Panel
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• If engine is to be cranked at starting RPM without starting (e.g. for compression testing), disconnect the four connectors for ignition coils, using the ignition coil puller T40039 --> Ignition coils with power output stage, removing and installing. Also remove fuse from Fuel Pump (FP) Control Module J538.

NOTE:

The fuse is located in the fuse carrier in the instrument panel. By removing fuse - 28 - , the voltage supply to terminal 30 for the Fuel Pump (FP) Control Module J538 is interrupted.

Cleanliness rules and instructions for working on fuel system

Even minor contaminations can lead to malfunctions in the fuel injection system. Therefore when working on the fuel supply/injection system, pay careful attention to the following rules of cleanliness:

• Before loosening, connections and surrounding areas must be cleaned thoroughly with engine or brake cleaner, and then cleaned area must be dried completely.
• Plug open lines and connections immediately with appropriate protective caps.
• Place parts that have been removed on a clean surface and cover them. Use lint free cloths.
• Only install clean components: Only unpack replacement parts immediately prior to installation. Do not use parts that have been stored unpackaged (e.g. in tool boxes etc.).

• When the system is open: Do not work with compressed air. Do not move vehicle unless absolutely necessary.

Procedure that must be performed before opening the high-pressure fuel injection system - Pay close attention!

Fig. 2: Identifying Main Fuse Panel
Courtesy of VOLKSWAGEN UNITED STATES, INC.

For safety reasons, if the battery is not disconnected, fuse - 28 - from the Fuel Pump (FP) Control Module J538 must be removed before opening fuel system. Otherwise, the fuel pump will be activated by the drivers door contact switch.

NOTE:

The fuse is located in the fuse carrier in the instrument panel. By removing fuse - 28 - , the voltage supply to terminal 30 for the Fuel Pump (FP) Control Module J538 is interrupted.

CAUTION:

The fuel injection system is divided into a high pressure section (maximum approx. 110 bar) and a low pressure system (approx. 6 bar). Before opening high pressure parts, e.g. removing high pressure pump, fuel rail, fuel injectors, fuel pipes or Fuel Pressure Sensor G247 G247 , fuel pressure in high pressure area must be reduced to a residual pressure of approx. 6 bar. The procedure for this is as follows.

High fuel pressure, reducing

Special tools, testers and auxiliary items required

Fig. 3: Identifying Assembly Tool T10118
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Assembly tool T10118

Fig. 4: Removing Electrical Connector From Fuel Pressure Regulator Valve N276 Using Assembly Tool T10118
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove electrical connector - 2 - from Fuel Pressure Regulator Valve N276 using the Assembly Tool T10118.
• Allow engine to idle approx. 10 seconds.

NOTE:

By removing the electrical connector from the Fuel Pressure Regulator Valve N276 in idle, the fuel pressure is reduced from approx. 50 bar to approx. 6 bar. The decreasing fuel pressure can be decreased if a Vehicle Diagnosis and Service Syst. VAS 5052 VAS 5052 is connected and engine control module is selected. And select display group 140 under "Read measured value block" function. Fuel pressure (actual value) is shown in display field 3.

• Switch off ignition.

CAUTION:

The fuel lines will continue to be filled with fuel, but will no longer be under high pressure. To open fuel system, wear protective eyewear and clothing to prevent injuries and contact with skin. Before opening the high pressure system, place a cloth around the connection.

• After reducing high pressure, high pressure system can be opened. To do this, place a clean cloth around connection to reduce residual pressure in system to approx. 7 bar. Escaping fuel must be absorbed.

NOTE:

If the high pressure line is not opened immediately, the fuel pressure can increase slightly.

• Connector Vehicle Diagnosis and Service Syst. VAS 5052 and generate the readiness code in the engine control module in "Guided Fault Finding" operating mode.

Technical data

Engine data			2.0L/125 kW/147 kW/162 kW Turbo FSI engine
Idle speed cannot be adjusted, it is regulated by idle stabilization			640 to 800 RPM
Engine speed limitation via fuel injector shut-off			6500 RPM
Fuel pressure		Fuel supply-pressure up to high-pressure pump, (is produced by an electric fuel pump in the fuel tank)	Approx. 6.0 bar pressure with ignition on
		Fuel high pressure (produced by a mechanical single-piston pump) at approx. 85 degree coolant temperature	Approx. 50 bar positive pressure at idle Approx. 110 bar positive pressure at certain operating points.

Overview of component locations

Components A through R are not depicted in the exploded view illustration.

Fig. 5: Overview Of Component Locations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Mass air flow (MAF) sensor G70

• Mass Air Flow (MAF) Sensor G70 - 1 -

2 - Heated Oxygen Sensor (HO2S) G39 and Oxygen Sensor (O2S) Heater Z19

• Removing and installing --> Heated Oxygen Sensor (HO2S) G39 and Oxygen Sensor (O2S) Heater Z19 before catalytic converter, removing and installing

3 - Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 and Oxygen Sensor (O2S) Heater 1 (behind Three Way Catalytic Converter (TWC)) Z29

• Oxygen sensors
• Removing and installing --> Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 and Oxygen Sensor (O2S) Heater 1 (behind Three Way Catalytic Converter (TWC)) Z29 , removing and installing

4 - Engine Coolant Temperature (ECT) Sensor G62

• Engine Coolant Temperature (ECT) Sensor G62 - 1 -

5 - Camshaft Adjustment Valve 1 N205

• and under Camshaft Adjustment Valve 1 N205 - 1 - and Fuel Pressure Regulator Valve N276 - 2 -
• Removing and installing --> 15 - ENGINE - CYLINDER HEAD, VALVETRAIN

6 - Fuel Pressure Regulator Valve N276

• and under Camshaft Adjustment Valve 1 N205 - 1 - and Fuel Pressure Regulator Valve N276 - 2 -

7 - Single piston high pressure pump

• Removing and installing --> High pressure pump, removing and installing

8 - Low Fuel Pressure Sensor G410

• 15 Nm

9 - Intake Flap Motor V157 with Intake Manifold Runner Position Sensor G336

• After replacing the fuel rail, the Intake Manifold Runner Position Sensor G336 must be adapted to the Engine Control Module (ECM) J623 again, "Guided Functions"

10 - Engine speed (RPM) sensor G28

• Electrical harness connectors

11 - 6-pin harness connector

• For Heated Oxygen Sensor (HO2S) G39 and Oxygen Sensor (O2S) Heater Z19 (black) Electrical harness connectors

12 - 6-pin harness connector

• Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 and Oxygen Sensor (O2S) 1 (behind Three Way Catalytic Converter (TWC) Heater Z29 (brown connector) Electrical harness connectors

13 - Evaporative Emission (EVAP) Canister Purge Regulator Valve N80

14 - Engine Control Module J623

• Removing and installing --> Engine Control Module (ECM) J623 , replacing

15 - Charge Air Pressure Sensor G31

• Charge Air Pressure Sensor G31 - 1 -
• Removing and installing --> 21 - TURBOCHARGER, G-CHARGER

16 - Throttle Valve Control Module J338 , 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
• After replacing the Throttle Valve Control Module J338 , it must be adapted to the Engine Control Module (ECM) J623 again (basic setting, display group 60) see "Guided Functions"
• Intake Air Temperature (IAT) Sensor G42 - 1 - Throttle Valve Control Module J338 - 2 -

17 - Intake Air Temperature (IAT) Sensor G42

• Intake Air Temperature (IAT) Sensor G42 - 1 - Throttle Valve Control Module J338 - 2 -

18 - Fuel Pressure Sensor G247

• 22 Nm
• (Torque Specification 22 Nm) under Fuel Pressure Sensor G247 - 1 - (Torque Specification 22 Nm)

19 - Camshaft Position (CMP) Sensor G40

• Camshaft Position (CMP) Sensor G40 - 1 -

20 - Ignition coils with power output stages

• Ignition Coil 1 with Power Output Stage N70
• Ignition Coil 2 with Power Output Stage N127
• Ignition Coil 3 with Power Output Stage N291
• Ignition Coil 4 with Power Output Stage N292

• The ignition coils must be pulled out of cylinder head using ignition coil puller T40039
• Removing and installing --> Ignition coils with power output stage, removing and installing

21 - Turbocharger Recirculating Valve N249

• Installed directly on turbocharger Components on turbocharger
• Removing and installing --> 21 - TURBOCHARGER, G-CHARGER

22 - Wastegate Bypass Regulator Valve N75

• Installed directly on turbocharger Components on turbocharger
• Removing and installing --> 21 - TURBOCHARGER, G-CHARGER

A - Data Link Connector (DLC)

• In knee bolster on drivers side

B - Fuel Pump (FP) Control Module J538

• Fuel Pump (FP) Control Module J538 - 1 -
• If Fuel Pump (FP) Control Module J538 or fuel pump is replaced, an adaptation must be performed "Initiate basic setting" display group 103
• Check Fuel Pump (FP) Control Module J538 --> 20 FUEL SUPPLY .

C - "EPC" Warning lamp

• In instrument cluster

D - Emission Malfunction Indicator Lamp "MIL"

• In instrument cluster

E - 8-pin harness connector for fuel injectors

• Component locations beneath intake manifold

F - Connector

• For Camshaft Position (CMP) Sensor G40 and Fuel Pressure Sensor G247
• Component locations beneath intake manifold

G - Brake Light Switch F and Brake Pedal Switch F63

• Installed location Brake Light Switch F/Brake Pedal Switch F47 , Clutch Pedal Switch F36

H - Throttle Position (TP) Sensor G79 and Accelerator Pedal Position Sensor 2 G185

• On accelerator pedal (both sensors are stored in one housing)

I - Clutch pedal switch F36

• Installed location Brake Light Switch F/Brake Pedal Switch F47 , Clutch Pedal Switch F36

J - Relay and fuse carrier in E-box

• Installed location in 4-socket relay carrier, plenum chamber E-box

K - Coolant Fan Control (FC) control module J293

• Installed in left coolant fan, when facing driving direction

L - Fuel injector

• In fuel rail line
• Cylinder 1 Fuel Injector N30
• Cylinder 2 Fuel Injector N31
• Cylinder 3 Fuel Injector N32

• Cylinder 4 Fuel Injector N33
• Removing and installing --> Fuel injectors, removing and installing

Fuel injectors referred to here are high pressure fuel injectors. They inject fuel directly into the cylinder under high pressure (max. approx. 120 bar).

M - Knock Sensor (KS) I G61

• For cylinder 1 and 2
• Torque specification: 20 Nm
• Component locations beneath intake manifold

N - Knock sensor 2 G66

• For cylinder 3 and 4
• Torque specification: 20 Nm
• Component locations beneath intake manifold

O - Oil pressure switch F1

• Electrical harness connectors
• Checking, removing and installing --> 17 - ENGINE - LUBRICATION

P - Oil Level Thermal Sensor G266

• Oil Level Thermal Sensor G266

Q - Leak detection pump (LDP) V144

• Only installed on engine code BPG

R - Left Electro-Hydraulic Engine Mount Solenoid Valve N144

• Only installed on vehicles with automatic transmission

Fuel Pressure Sensor G247 - 1 - (Torque Specification 22 Nm)

Fig. 6: Fuel Pressure Sensor G247
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• The torque specification of the connection is "30 Nm" , and must be checked before installing the Fuel Pressure Sensor G247.

Camshaft Position (CMP) Sensor G40 - 1 -

Fig. 7: Camshaft Position (CMP) Sensor G40
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Mass Air Flow (MAF) Sensor G70 - 1 -

Fig. 8: Mass Air Flow (MAF) Sensor G70
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Camshaft Adjustment Valve 1 N205 - 1 - and Fuel Pressure Regulator Valve N276 - 2 -

Fig. 9: Camshaft Adjustment Valve 1 N205 And Fuel Pressure Regulator Valve N276
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Intake Air Temperature (IAT) Sensor G42 - 1 - Throttle Valve Control Module J338 - 2 -

Fig. 10: Intake Air Temperature (IAT) Sensor G42 Throttle Valve Control Module J338
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fuel Pump (FP) Control Module J538 - 1 -

Fig. 11: Fuel Pump (FP) Control Module J538
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• If the Fuel Pump (FP) Control Module J538 or fuel pump is replaced, an adaptation must be performed "Initiate basic setting" display group 103
• Check Fuel Pump (FP) Control Module J538 --> 20 FUEL SUPPLY .

Electrical harness connectors

Fig. 12: Disconnecting 4-Pin Electrical Harness Connector From Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Heated Oxygen Sensor (HO2S) G39 and Oxygen Sensor (O2S) Heater Z19 (black connector)

2 - Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 and Oxygen Sensor (O2S) Heater 1 (behind Three Way Catalytic Converter (TWC)) Z29 (brown connector)

Oxygen sensors

Fig. 13: Identifying Oxygen Sensors
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 and Oxygen Sensor (O2S) Heater 1 (behind Three Way Catalytic Converter (TWC)) Z29

2 - Heated Oxygen Sensor (HO2S) G39 and Oxygen Sensor (O2S) Heater Z19

Installed location of Engine Control Module (ECM) J623

Fig. 14: Installed Location Of Engine Control Module (ECM) J623
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Engine Coolant Temperature (ECT) Sensor G62 - 1 -

Fig. 15: Engine Coolant Temperature (ECT) Sensor G62
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Installed location Brake Light Switch F/Brake Pedal Switch F47 , Clutch Pedal Switch F36

Fig. 16: Installed Location Brake Light Switch F/Brake Pedal Switch F47 , Clutch Pedal Switch F36
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1. Brake light switch F , Brake pedal switch F47
2. Clutch pedal switch F36

NOTE:

To ensure that they are absolutely securely seated, the switches may only be installed once.

Installed location in 4-socket relay carrier, plenum chamber E-box

Fig. 17: Installed Location In 4-Socket Relay Carrier, Plenum Chamber E-Box
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1.1 - Not used

1.2 - Starting Interlock Relay J207

2 - Motronic Engine Control Module (ECM) Power Supply Relay J271

3 - Engine Component Power Supply Relay J757

Installed location on 9-socket relay carrier in driver footwell

Fig. 18: Installed Location On 9-Socket Relay Carrier In Driver Footwell
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Arrow - Fuel Pump (FP) Relay J17

Electrical harness connectors

Fig. 19: Electrical Harness Connectors
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Oil Pressure Switch F1

2 - 3-pin connector (gray) for Engine Speed (RPM) Sensor G28

3 - Engine Speed (RPM) Sensor G28

Component locations beneath intake manifold

Fig. 20: Component Locations Beneath Intake Manifold
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Knock Sensor (KS) 1 G61

2 - Knock Sensor (KS) 2 G66

3 - Oil Pressure Switch F1 in oil filter bracket

4 - 3-pin connector (gray) for Engine Speed (RPM) Sensor G28

5 - Electrical connector for Camshaft Position (CMP) Sensor G40 and Fuel Pressure Sensor G247

6 - 8-pin harness connector for fuel injectors

Charge Air Pressure Sensor G31 - 1 -

Fig. 21: Charge Air Pressure Sensor G31
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• O-ring, replace
• Tighten to 5 Nm
• Removing and installing --> 21 - TURBOCHARGER, G-CHARGER

Oil Level Thermal Sensor G266

Fig. 22: Oil Level Thermal Sensor G266
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Components on turbocharger

Fig. 23: Components On Turbocharger
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Turbocharger

2 - Tighten Wastegate Bypass Regulator Valve N75 to 3 Nm.

3 - Tighten Turbocharger Recirculating Valve N249 to 7 Nm (observe installed location, next illustration)

Fig. 24: Installation Position Of Turbocharger Recirculating Valve N249
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Observe installed location of Turbocharger Recirculating Valve N249

Air filter, assembly overview

Fig. 25: Air Filter, Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Not installed

2 - Air guide hose

• To turbocharger
• Check the air duct hose for dirt and leaves

3 - Hose clamp

4 - Mass air flow (MAF) sensor G70

• Removing and installing --> Mass Air Flow (MAF) Sensor G70 , removing and installing

5 - Bolt

• 1.5 Nm

6 - Air duct

• To lock carrier

7 - Bolt

• 1.5 Nm
• On lock carrier

8 - Air duct

• To air filter housing
• Clean the air channel of debris and leaves

9 - Spreader clip

10 - Bolt

• 1.5 Nm

11 - Upper part of air filter housing

• Clean air filter housing-upper part of salt residue, dirt and leaves

12 - Heat shield

13 - Bolt

• 1.5 Nm

14 - Air filter element

• Always use a genuine air filter element
• Removing and installing --> Air filter insert, removing and installing
• Observe change intervals -->
  • 01 - MAINTENANCE
  • 01 - MAINTENANCE for MAINTENANCE PROCEDURES - CABRIOLET

15 - Lower part of air filter housing

• Clean the air filter housing-lower part of salt residue, dirt and leaves
• Using pressurized air, blow out the water drain (small hole) in the lower part of the air filter housing.

16 - O-ring

• Replace if damaged

17 - Not installed

Engine cover, removing and installing

Removing

Fig. 26: Removing Engine Cover
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Carefully remove engine cover from retaining pins. Do not remove engine cover one-sidedly or in a jerking manner.

Installing

• To prevent damage, do not hit engine cover with fist or tools.
• Position the engine cover (observe oil filler tube and oil dipstick) on the engine.
• Using both hands, press the engine cover into the rubber sleeves.

Air filter insert, removing and installing

Air filter installing, removing

Fig. 27: Disconnecting Electrical Harness Connector From Mass Air Flow (MAF) Sensor G70
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disconnect the electrical connector - 1 - from Mass Air Flow (MAF) Sensor G70.

Fig. 28: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove both bolts - arrows - from the air duct, at the lock carrier.
• Disconnect air duct - 2 - from air filter housing.
• Open the hose clamp on air duct hose to turbocharger and pull it off at Mass Air Flow (MAF) Sensor G70.

Fig. 29: Identifying Upper Part Of Air Filter Bolts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove both bolts - 1 - at upper part of air filter and lift the upper part of air filter upward and out.
• Remove the old filter element.

Air filter installing

For problem-free operation of the mass air flow (MAF) sensor G70 it is very important to observe the following notes and procedures.

NOTE:

If the air filter element is very dirty or soaked, dirt particles or moisture may have contaminated the Mass Air Flow (MAF) Sensor G70 and may be causing false mass air flow values. This results in a reduction of power, since a lower injection quantity is calculated. Always use an original equipment air filter element. Hose connections and charge air system hoses must be free of oil and grease before installing. When installing, do not use any lubricants containing silicone. The air filter housings must be absolutely clean. Secure all hose connections using hose clamps appropriate for the model type Note the following when blowing out the air filter housing with pressurized air: To prevent malfunctions, cover the critical air flow components, such as Mass Air Flow (MAF) Sensor, air intake tubes, etc., with a clean rag. Observe disposal regulations!

• Using pressurized air, blow out the water drain (small hole) in the lower part of the air filter housing.
• Clean air filter housing (upper and lower sections) of salt residue, dirt or leaves (use vacuum cleaner if necessary).
• Check the Mass Air Flow (MAF) Sensor and air duct hose (intake air side) for salt residue, dirt, and leaves.
• Check the air duct from lock carrier to air filter housing for dirt and leaves.

• Make sure that 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 the air filter element (observe sealing lip of air filter element).
• Make sure air duct hose is securely seated on Mass Air Flow (MAF) Sensor G70.

Further installation is performed in reverse order.

Mass Air Flow (MAF) Sensor G70 , removing and installing

Removing

Fig. 30: Disconnecting Electrical Harness Connector From Mass Air Flow (MAF) Sensor G70
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disconnect electrical connector - 1 - from mass air flow (MAF) sensor G70.

Fig. 31: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove both bolts - arrows - of the air duct at the lock carrier.
• Disconnect air duct - 2 - from air filter housing.
• Open hose clamp on air duct hose to turbocharger and pull it off at Mass Air Flow (MAF) Sensor G70.
• Remove both bolts from Mass Air Flow (MAF) Sensor G70.

• Carefully pull the Mass Air Flow (MAF) Sensor G70 out of the guide from air filter housing.

Installing

For problem-free operation of the Mass Air flow (MAF) Sensor G70 it is very important to observe the following notes and procedures.

NOTE:

If the air filter element is very dirty or soaked, dirt particles or moisture may have contaminated the Mass Air Flow (MAF) Sensor G70 and may be causing false mass air flow values. This results in a reduction of power, since a lower injection quantity is calculated. Always use an original equipment air filter element. Use a lubricant (silicone-free) for installing the air duct hose. Secure all hose connections using hose clamps appropriate for the model type

• Check Mass Air Flow (MAF) Sensor and air duct hose (intake air side) for salt residue, dirt, and leaves.
• Check intake ducting up to the air filter element for dirt. If any contaminants are discovered, clean the air filter housing (upper and lower parts) of salt residue, dirt and leaves (if necessary, clean by washing or vacuuming). Air filter, removing and installing --> Air filter insert, removing and installing

Installation is in reverse order of removal.

Intake Manifold, assembly overview

Fig. 32: Intake Manifold, Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Intake Air Temperature (IAT) Sensor 2 G299 bolt

• 5 Nm

2 - Intake Air Temperature (IAT) Sensor 2 G299

3 - Intake manifold

• Removing and installing --> Intake manifold with fuel rail, removing and installing

4 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 1 N80

5 - Bolt for single-piston high-pressure pump

• 3 pieces
• 10 Nm

6 - Fuel Pressure Regulator Valve N276

7 - Mechanical single-piston high-pressure pump

• With Fuel Pressure Regulator Valve N276 and Low Fuel Pressure Sensor G410
• An electrical fuel pump, located in the fuel tank, supplies fuel to the mechanical high-pressure pump at a pressure of approx. 6 bar.
• When installing the high-pressure pump, make sure that no dirt enters the fuel system.
• The fuel system must be pressureless, releasing fuel pressure --> Procedure that must be performed before opening the high-pressure fuel injection system - Pay close attention!

• Do not install fuel lines with tension
• Removing and installing --> High pressure pump, removing and installing

8 - Connection for fuel return line to fuel tank

• Replace bolt
• Tighten connection to 40 Nm (before each installation of the fuel line, check the torque of the connection)
• Do not install fuel line with tension (be aware of cleanliness) Torque specification: 25 Nm

9 - Fuel supply line to fuel rail

• Tighten connection to 30 Nm (before each installation of the fuel line, check the torque of the connection)
• Do not install fuel line with tension (be aware of cleanliness) Torque specification: 30 Nm

10 - Intake Flap Motor V157 with Intake Manifold Runner Position Sensor G336

• After replacement of the fuel rail, the Intake Manifold Runner Position Sensor G336 must be adapted to the Engine Control Module (ECM) J623 again, "Guided Functions"

11 - Bolt for the Intake Flap Motor V157 with Intake Manifold Runner Position Sensor G336

• 3 pieces
• 7 Nm

12 - Intake manifold support

13 - Bolt for the intake manifold support

• 23 Nm

14 - Throttle Valve Control Module J338 , Throttle Drive (for Electronic Power Control (EPC)) G186

• With Throttle Drive Angle Sensor 1 (for Electronic Power Control (EPC)) G187 and Throttle Drive Angle Sensor 2 (for Electronic Power Control (EPC)) G188
• After replacing the Throttle Valve Control Module J338 , it must be adapted to the Engine Control Module (ECM) J623 again (basic setting, display group 60) see "Guided Fault Finding"

15 - Bolt for Throttle Valve Control Module J338

• 4 pieces
• 7 Nm

16 - Nut for intake manifold support

• 10 Nm

17 - Seal

• Replace

18 - Fuel rail

• Removing and installing --> Fuel rail, removing and installing

19 - Fuel Pressure Sensor G247

• 20 Nm

Fuel rail, assembly overview

Fig. 33: Fuel Rail, Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Radial adjustment

• Replace if damaged

2 - Fuel injector

• With combustion chamber seal (Teflon seal), always replace
• Replace O-Rings
• Note correct installation position
• Removing and installing --> Fuel injectors, removing and installing

3 - Support ring

4 - Fuel rail

• Removing and installing --> Fuel rail, removing and installing

5 - Fuel Pressure Sensor G247

• 22 Nm
• Tighten connections to 30 Nm

6 - Low Fuel Pressure Sensor G410

• 15 Nm

7 - Fuel Pressure Regulator Valve N276

8 - Mechanical single-piston high-pressure pump

• With Fuel Pressure Regulator Valve N276 and Low Fuel Pressure Sensor G410
• An electrical fuel pump, located in the fuel tank, supplies fuel to the mechanical high-pressure pump at a pressure of approx. 6 bar.
• When installing the high-pressure pump, make sure that no dirt enters the fuel system.
• The fuel system must be pressureless to install the high-pressure pump, releasing fuel pressure --> Procedure that must be performed before opening the high-pressure fuel injection system - Pay close attention!

• Do not install fuel lines with tension
• Removing and installing --> High pressure pump, removing and installing

9 - Evaporative Emission (EVAP) Canister Purge Regulator Valve N80

10 - Throttle Valve Control Module J338 , Throttle Drive (for Electronic Power Control (EPC)) G186

• With Throttle Drive Angle Sensor 1 (for Electronic Power Control (EPC)) G187 and Throttle Drive Angle Sensor 2 (for Electronic Power Control (EPC)) G188
• After replacing the Throttle Valve Control Module J338 , it must be adapted to the Engine Control Module (ECM) J623 again (basic setting, display group 60) see "Guided Fault Finding"

11 - Intake Air Temperature (IAT) Sensor 2 G299

• Tighten to 5 Nm

12 - Bolts for intake manifold

• 9 Nm

13 - Intake manifold

• Removing and installing --> Intake manifold with fuel rail, removing and installing

Intake manifold with fuel rail, removing and installing

CAUTION:

Before opening a component of the high-pressure section, the fuel pressure must be released. Pay absolute attention to --> Procedure that must be performed before opening the high-pressure fuel injection system - Pay close attention!.

NOTE:

To access the fuel injectors, the intake manifold and the fuel rail with intake manifold runner control valve must be removed. (Depending on version, more or fewer work steps may be required). The combustion chamber seal (Teflon) and the O-ring must always be replaced. Intake manifold, overview --> Intake Manifold, assembly overview

Removing

• Remove engine cover --> Engine cover, removing and installing.
• Disconnect all electrical harness connectors from the intake manifold and fuel rail.
• Disconnect vacuum hose between intake manifold and vacuum pump from intake manifold.

NOTE:

This vacuum hose and the vacuum pump (attached to rear of cylinder head) are only installed on vehicles with automatic transmission.

Fig. 34: Disconnecting Fuel Line
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disconnect fuel line - arrow - (catch escaping fuel and plug the open connections immediately).

Fig. 35: Removing Both Bolts From Valve Cover/Coolant Pipe
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disconnect hose connections - arrows - from valve cover.

Fig. 36: Removing Both Bolts From Valve Cover/Coolant Pipe
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove both bolts - 1 and 2 - from coolant pipe.

Fig. 37: Removing Bolt From Oil Line And From Coolant Pipe
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove bolt from oil line - 1 - and from coolant pipe - 2 -.

Fig. 38: Identifying High Pressure Pump Fuel Lines
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove both fuel lines at high-pressure pump.
• Open hose clamps and pull intake hose off from Throttle Valve Control Module J338 and intake manifold.

Fig. 39: Identifying 3-Pin Connector From Fuel Pressure Sensor -G247-
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disconnect electrical connector - 1 - from Fuel Pressure Sensor G247.

Fig. 40: Identifying 3-Pin Connector From Fuel Pressure Sensor -G247-
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Pull oil dipstick out and remove bolt - 2 - for oil dipstick guide tube.

Fig. 41: Removing Bolt For Oil Line
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove bolt - 1 - for oil line.

Fig. 42: Removing Nut From Intake Manifold Support
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove nut - arrow - from intake manifold support (if necessary, remove Throttle Valve Control Module J338 to access the support nut).

Fig. 43: Separating Oil Dipstick Guide Tube At Separation Point And Removing Bolt For Intake Manifold Bracket
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Separate oil dipstick guide tube - 2 - at separation point and remove bolt - 1 - for intake manifold bracket.
• Remove all bolts from intake manifold.
• Carefully remove intake manifold with fuel rail from cylinder head.

NOTE:

The fuel injectors could remain stuck in the fuel rail.

• Fuel rail, removing and installing --> Fuel rail, removing and installing

Installing

• Installation is in reverse order of removal.

Torque specifications	Nm
Mounting bolts for intake manifold	9
Bolt for intake manifold support	23
Nut for intake manifold support	10
Fuel supply line to high pressure pump	30
Fuel return line to high pressure pump (replace)	25
Bolts for Intake Flap Motor V157	7

Fuel rail, removing and installing

If fuel rail is to be replaced, the Intake Manifold Runner Position Sensor G336 must be adapted to the Engine Control Module (ECM) J623 again, "Guided Functions"

NOTE:

Intake manifold must be removed, removing --> Intake manifold with fuel rail, removing and installing.

• Remove hoses from EVAP canister.
• To do so, open hose clamp - 1 -.

Fig. 44: Identifying Hose Clamp & Bolts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove both bolts - arrows - from fuel rail.
• Remove hose connection 1 from intake manifold and remove both bolts - arrows -.

Fig. 45: Removing/Installing Coupling Rod From Intake Flap Motor V157
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove both fuel lines - 2 and 3 -.
• Carefully pry off linkage from Intake Flap Motor V157 - 4 -.

Fig. 46: Removing/Installing Coupling Rod From Intake Flap Motor V157
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove Intake Flap Motor V157 - 5 -.

Fig. 47: Removing Fuel Rail From Intake Manifold
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Pry fuel rail off from the intake manifold via the retaining tabs - arrows -.
• Remove fuel rail from intake manifold.

Installing

• Installation is in reverse order of removal.
• Install intake manifold --> Intake manifold with fuel rail, removing and installing.

Fuel injectors, removing and installing

Removing

Remove intake manifold and fuel rail --> Intake manifold with fuel rail, removing and installing.

Removing fuel injectors, in the event that they are stuck in the fuel rail

Carefully pull fuel injectors out of the fuel rail.

Removing fuel injectors, in the event that they are stuck in the cylinder head

Special tools, testers and auxiliary items required

Fig. 48: Identifying Tool Set T10133
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Tool set with puller T10133 Tool Set T10133

Remove intake manifold and fuel rail --> Intake manifold with fuel rail, removing and installing.

Fig. 49: Identifying Fuel Injector, Individual Parts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

The illustration shows the fuel injector.

1 - Radial compensation, replace if damaged

2 - Combustion chamber sealing ring (Teflon sealing ring). Replace the sealing ring once removed. The sealing ring must not be greased or handled with any other lubricants when installing.

3 - Groove on fuel injector

4 - Spacer ring, replace if damaged

5 - O-ring (replace, coat lightly with clean engine oil when installing)

6 - Support ring (via this support ring, the fuel rail utilizes the force to hold the fuel injector in place in the cylinder head).

Fig. 50: Identifying Fuel Injector, Individual Parts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

With fuel injector installed, the radial adjustment - 1 - is clipped into the support ring - 6 -. To remove the fuel injector, the support ring must be separated from the fuel injector in order to install the puller T10133/2 into the indentation on the fuel injector - 3 -.

• Cover open intake channels with a clean rag.
• Disconnect electrical harness connector at fuel injector that is to be removed.

Fig. 51: Bending Retaining Tabs Of Radial Compensation To Side
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Bend retaining tabs of radial compensation to the side using a screwdriver and pull off support ring from fuel injector.

Fig. 52: Installing Hammer T10133/3 To Puller T10133/2
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Assemble the slide hammer T10133/3 - 1 - and the injector puller T10133/2 - 2 -. Then, guide the puller T10133/2 into the groove on the fuel injector and carefully drive the fuel injector out. It is possible that this will destroy the radial compensation (retaining tabs break). This must be replaced when re-installing fuel injector.

NOTE:

The combustion chamber seal must always be replaced before re-installing the fuel injector --> Combustion chamber sealing ring (Teflon sealing ring), replacing.

Combustion chamber sealing ring (Teflon sealing ring), replacing

NOTE:

The combustion chamber seal must always be replaced before re-installing the fuel injector.

Fig. 53: Identifying Fuel Injector, Individual Parts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• The illustration shows the fuel injector.

1 - Radial compensation, replace if damaged

2 - Combustion chamber sealing ring (Teflon sealing ring), replace, the ring must not be greased or handled with any other lubricants when installing.

3 - Groove on fuel injector

4 - Spacer ring, replace if damaged

5 - O-ring (replace, coat lightly with clean engine oil when installing)

6 - Support ring (via this support ring, the fuel rail utilizes the force to hold the fuel injector in place in the cylinder head).

• Carefully remove the old Teflon seal with the appropriate tool (e.g. with cut the seal open with a razor and spread seal open with a small screwdriver and pull it forward and off.) When doing this, make sure not to damage the groove and circumferential rib in the groove base.

NOTE:

If the groove is damage, the fuel injector must be replaced.

• Before installing the new Teflon seal, the seal groove and the shaft of the fuel injector must be cleaned of combustion residue using a clean rag.

NOTE:

A fuel injector with "angled connector" is shown in the illustration. Do not pay attention to this for the remainder of the procedure, because it is unrelated to replacement of the combustion chamber seal.

Fig. 54: Placing Assembly Cone T10133/5 With New Teflon Seal Onto Fuel Injector
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Place the assembly cone T10133/5 with the new Teflon seal - 1 - onto the fuel injector - 2 -.

Fig. 55: Pushing Teflon Seal Further Onto Assembly Cone T10133/5
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Using the assembly sleeve T10133/6 , push the Teflon seal further onto the assembly cone T10133/5 until the Teflon seal is engaged in the seal groove. When doing this, do not use any lubricants.

NOTE:

By pushing the Teflon seal onto the fuel injector, the Teflon seal is expanded. For this reason, the Teflon seal must be contracted again, once it has been pushed on. This is done in two steps. The procedure for this is as follows.

The 1st step of calibrating (adapting) the Teflon seal is performed using the calibration sleeve T10133/7.

Fig. 56: Pushing Calibration Sleeve T10133/7 Over Fuel Injector Up To Stop
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Using a rotating motion (approx. 180) and light pressure, push the calibration sleeve T10133/7 over the fuel injector up to the stop. Pull the calibration sleeve T10133/7 off again, rotating it in the opposite direction.

The 2nd step of calibrating (adapting) the Teflon seal is performed using the calibration sleeve T10133/8.

Fig. 57: Pushing Calibration Sleeve T10133/8 Over Fuel Injector Up To Stop
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Using a rotating motion (approx. 180) and light pressure, push the calibration sleeve T10133/8 over the fuel injector up to the stop. Pull the calibration sleeve T10133/8 off again, rotating it in the opposite direction.
• Replace O-ring on fuel injector. Moisten the O-ring with clean engine oil before installing.
• The Teflon seal must not be oiled.

Fig. 58: Cleaning Bores For High Pressure Fuel Injectors In Cylinder Head Using Nylon Brush T10133/4
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Using the included nylon brush T10133/4 , thoroughly clean the fuel injector bores in the cylinder head before installing the fuel injectors.

NOTE:

An opened intake valve hinders the cleaning of the bore. In this case, the engine must be turned further by hand using a wrench on the crankshaft.

Fig. 59: Installing Fuel Injector Again With Support Ring And Clipping In Radial Compensation On Support Ring
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Install fuel injector again with support ring - 1 - and clip in radial compensation - 2 - on support ring.

Fig. 60: Using Assembly Drift T10133/9 To Press Fuel Injector Into Hole In Cylinder Head Until It Stops
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Using assembly drift T10133/9 , press the fuel injector into the fuel injector bore in the cylinder head until it stops. Make sure the fuel injectors are positioned correctly in cylinder head.
• Further installation is in reverse order of removal.
• Install intake manifold with fuel rail --> Fuel rail, removing and installing

Fuel pressure and residual pressure before high pressure pump, checking

Special tools, testers and auxiliary items required

Fig. 61: Identifying Pressure Gauge V.A.G 1318
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Fuel inj. Pressure Gauge VAG1318
• Adapter V.A.G 1318/11
• Adapter V.A.G 1318/12

Fig. 62: Identifying Remote Control Connection V.A.G 1348/3A
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remote Control V.A.G 1348/3A with adapter cable V.A.G 1348/3-3
• Measuring container, fuel-resistant

Fig. 63: Identifying Main Fuse Panel
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Test conditions:

• Battery voltage at least 12.5 Volts.
• Fuse on fuse panel S228 (position 28) OK.

Fig. 64: Identifying Fuel Pump (FP) Control Module J538 Electrical Harness Connector
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Fuel Pump (FP) Control Module J538 OK; checking
• Fuel filter OK.
• Fuel tank minimum ¹ /₄ full.

Test sequence

• Switch off ignition.

Sedan:

• Remove carpeting in luggage compartment.
• Fold forward the right backrest of rear seat, if necessary.

Wagon:

• Remove left 1/3 backrest -->
  • 72 - SEAT - FRAMES
  • 72 - SEAT - FRAMES for BODY INTERIOR - CABRIOLET
  .
• Remove left side trim in luggage compartment and dirt tray -->
  • 70 - INTERIOR TRIM
  • 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET
  .

All:

Fig. 65: Unbolting Cover For Locking Flange In Luggage Compartment
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove locking flange cover - arrows -.

Fig. 66: Disconnecting Electrical Harness Connector At Locking Flange
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disconnect electrical harness connector - arrow - at locking flange.

Fig. 67: Connecting Other End Of Hand Held Remote Starter (Jumper) To Vehicle Battery (+)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Connect remote control V.A.G 1348/3 A with connection V.A.G 1348/3-3 to contact - 1 - using an adapter cable from the connector test set V.A.G 1594 C.
• Using insulating tape, tape over the second contact of adapter cable V.A.G 1348/3-3 to prevent a short circuit - arrow -.
• Connect contact - 4 - to vehicle Ground (GND) using a jumper cable from connector test set V.A.G 1594 C.
• Connect alligator clip to vehicle battery (positive).

• Remove fuel filler cap from fuel filler tube.

Fig. 68: Removing Engine Cover
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove engine cover - arrows -.

CAUTION:

Fuel system is under pressure! Before opening system, place clean rags around the connection. Then release pressure by carefully loosening the connection.

Fig. 69: Disconnecting Fuel Line
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disconnect fuel supply line - arrow -.

Fig. 70: Connecting Pressure Gauge V.A.G 1318 To Fuel Supply Line Using Adapters V.A.G 1318/11 And V.A.G 1318/12
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Connect pressure gauge V.A.G 1318 to fuel supply line using adapter V.A.G 1318/11 and V.A.G 1318/12.
• Connect bleed hose - arrow - to the Pressure Gauge V.A.G 1318 and hold it in a measuring container.
• Open shut-off valve of pressure gauge V.A.G 1318. The shut off valve lever points in the direction of flow.
• Bleed fuel system by pressing remote control briefly.

Fig. 71: Locating V.A.G 1318 Shut-Off Tap
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Close shut-off valve on Pressure Gauge V.A.G 1318. The shut off valve lever points in the direction of flow. - arrow -.
• Hold switch of the remote control until no more pressure increase is observed on the Pressure Gauge V.A.G 1318.

• Specified value: approx. 6 bar (5 to 7 bar) positive pressure.

If specification is not obtained:

• Check delivery rate of fuel pump --> 20 FUEL SUPPLY .

Checking residual pressure

• Check for leaks and residual pressure by observing pressure drop on Pressure Gauge V.A.G 1318.

• After 10 minutes there must be a residual pressure of at least 3.75 bar.

The holding pressure drops below 3.75 bar:

• Check connection between fuel Pressure Gauge V.A.G 1318 and fuel line for leaks.
• Check Pressure Gauge V.A.G 1318 for leaks.
• Check fuel lines and their connections for leaks.
• Replace fuel filter with integrated fuel pressure regulator --> 20 FUEL SUPPLY . Then repeat test.

• If the fuel filter is OK, replace fuel pump --> 20 FUEL SUPPLY .

Assembly is in reverse order of removal, note the following:

Fig. 72: Connecting Pressure Gauge V.A.G 1318 To Fuel Supply Line Using Adapters V.A.G 1318/11 And V.A.G 1318/12
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Switch off ignition.

NOTE:

Before disconnecting pressure gauge, release pressure by opening shut-off valve. Hold collecting container in front of hose.

• Tighten fuel supply line (ensure cleanliness).

Torque specifications

Component	Nm
Fuel line to fuel rail	22

High pressure pump, assembly overview

CAUTION:

Fuel system is under high pressure! Before opening the system, perform the procedure for releasing fuel pressure. Procedure, see --> Procedure that must be performed before opening the high-pressure fuel injection system - Pay close attention!

Fig. 73: High Pressure Pump, Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Air deflector plates

• Removable
• Check for damages and correct positioning

2 - Sleeve

• Remains inserted in cylinder head after removing the high-pressure pump, removable

3 - O-ring

• Always replace

4 - Mechanical single-piston high-pressure pump

• An electrical fuel pump, located in the fuel tank, supplies fuel to the mechanical high-pressure pump at a pressure of approximately. 6 bar.
• When installing the high-pressure pump, make sure that no dirt enters the fuel system.
• The fuel system must be pressureless. Releasing fuel pressure --> Procedure that must be performed before opening the high-pressure fuel injection system - Pay close attention!
• Do not install fuel lines with tension

• Removing and installing --> High pressure pump, removing and installing

5 - Fuel Pressure Regulator Valve N276

6 - Low Fuel Pressure Sensor G410

• 15 Nm

7 - Bolts for high-pressure pump

• Torx bolts (Qty. 3)
• 9 Nm

8 - Connection for fuel return line to fuel tank

• Replace bolt
• Tighten connection to 40 Nm (before each installation of the fuel line, check the torque of the connection)
• Do not install fuel line with tension (be aware of cleanliness) Torque specification: 25 Nm

9 - Fuel supply line to fuel rail

• Tighten connection to 30 Nm (before each installation of the fuel line, check the torque of the connection)
• Do not install fuel line with tension (be aware of cleanliness) Torque specification: 30 Nm

10 - Hole in cylinder head for high-pressure pump

11 - Fuel injector

• Replace O-Rings
• Note correct installation position
• Removing and installing --> Fuel injectors, removing and installing

High pressure pump, removing and installing

CAUTION:

Fuel system is under high pressure! Before opening the system, perform the procedure for releasing fuel pressure. Procedure, see --> Procedure that must be performed before opening the high-pressure fuel injection system - Pay close attention!

NOTE:

The removal and installation of the high-pressure fuel pump can only be performed on a cold engine. When installing the high-pressure fuel pump, make sure that no dirt enters the fuel system. Catch escaping fuel with a rag. The O-ring must always be replaced. High-pressure fuel lines must always be fastened free of tension.

Removing

• Disconnect electrical connectors from Low Fuel Pressure Sensor G410 and from Fuel Pressure Regulator Valve N276 - 1 and 2 -.
• Remove both fuel lines.

Fig. 74: Identifying Bolts, 3-Pin Connector, Low Fuel Pressure Sensor -G410-, 2-Pin Connector And Fuel Pressure Regulator Valve -N276-
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove 3 bolts - arrows -.
• Carefully pull out high-pressure fuel pump. The sleeve may remain inserted in the cylinder head.

Installing

• Replace O-ring for the high-pressure pump.
• Carefully place high-pressure pump with the sleeve into the opening in the cylinder head.
• Tighten bolts in diagonal sequence to 10 Nm.
• Before installing the fuel lines, check the torque of the connections on the high-pressure pump.

Torque specification for the connection of fuel return line: 40 Nm

Torque specification for the connection of fuel supply line: 30 Nm

NOTE:

Replace the bolt for the fuel return line

• Install bolt for the fuel return line hand-tight. Align so it is free of stress.
• Hand-tighten the union nut for the fuel supply line. Align so it is free of stress.

Torque specification for the fuel return line: 25 Nm

Torque specification for the fuel supply line: 30 Nm

• Connect electrical connectors on Low Fuel Pressure Sensor G410 and for Fuel Pressure Regulator Valve N276.

NOTE:

Check fuel system for leaks.

Wiring and components, checking with Test box V.A.G 1598/42

NOTE:

The test box is designed with 105 pins. The connection cable can be separated from the test box. This means that as new engine control module (ECM) connectors are introduced in the future, only a new cable must be designed and no longer the entire test box. Fig. 75: Connecting Test Box V.A.G 1598/42 To Wiring Harness With Adapter Cable V.A.G 1598/39-1 Or Adapter Cable V.A.G 1598/39-2 Courtesy of VOLKSWAGEN UNITED STATES, INC. The smaller of the two connectors on the engine control module (ECM) is assigned with terminals 1 to 60. The larger of the two connectors is assigned with terminals 1 to 94. If a wiring connection to the engine control module (ECM) is to be tested, use the wiring diagrams to determine through which connector the wire leads to the engine control module (ECM). If it is a wire that leads to the 60-pin connector, e.g. the wire for activating the variable intake manifold valve, (T60/27) then connect the smaller of the two connectors adapter cable V.A.G 1598/391 to the input "A" of the test box V.A.G 1598/42 and measure to Pin 27. Fig. 76: Connecting Test Box V.A.G 1598/42 To Wiring Harness With Adapter Cable V.A.G 1598/39-1 Or Adapter Cable V.A.G 1598/39-2 Courtesy of VOLKSWAGEN UNITED STATES, INC. If a wiring connection leads to the 94-pin connector according to wiring diagram, connect the larger of the two connectors adapter cable V.A.G 1598/392 as follows. The connector designated with an "A" must be connected to input "A" of the test box V.A.G 1598/42 and the connector "B" must be connected to input "B" of the test box V.A.G 1598/42. The test box V.A.G 1598/42 is designed so that it can be connected simultaneously to the engine control module harness and the engine control module itself. This is advantageous because electronic engine control remains fully functional (e.g. measurement of signals with engine running) when the test box is attached. The procedures will indicate whether the engine control module is to remain connected to the test box or not.

CAUTION:

To avoid damaging electronic components, switch to the corresponding measuring range and observe all test conditions before connecting the test leads.

• Remove Engine Control Module (ECM) --> Engine Control Module (ECM) J623 , replacing.
• Connect test box V.A.G 1598/42 to wiring harness connector. Ground (GND) clip at test box must be clipped to battery minus. The procedures will indicate whether the engine control module is to be connected to the test box.
• Perform test as described in relevant repair sequences.

Installing engine control module (ECM)

Installation is performed in reverse order.

• Thereafter, the engine control module must be equipped with the metal retainer.
• Clean threaded holes for shear bolts of locking compound residue. Cleaning can be performed with a thread cutter (tap).
• Always use new shear bolts.
• Check DTC memory and, if necessary, erase it. After DTC memory is erased, a readiness code must be generated for the engine control module using "Guided Functions" operating mode.

NOTE:

When ending Guided Fault Finding, the tester attempts to erase the DTC memory of all control modules. If this is not successful, the remaining DTCs stored in memory must be corrected until all DTCs can be erased.

Engine Control Module (ECM) J623 , replacing

NOTE:

When connector is disconnected from the Engine Control Module (ECM), adaptation values are erased and content of DTC memory remains intact.

Removing

• Connect Vehicle Diagnostic, Testing and Information System VAS 5051B and select vehicle system "01 - Engine electronics". Thereby, the ignition must be switched on.

Fig. 77: VAS 5051 Tester Displaying Control Module Identification And Coding
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• On the screen of the vehicle diagnostic, testing, and information system VAS 5051B , the control module identification and coding are displayed.
• Allow the control module identification to be displayed and then print it out.
• Switch off ignition.
• Remove the rubber seal of plenum chamber cover in direction of arrow.

Fig. 78: Identifying Plenum Chamber Cover & Removing Rubber Seal
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove plenum chamber cover - 1 - toward front.
• Pry off both covers - 3 - using a screwdriver.

Fig. 79: Removing Securing Clips And Cowl
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Loosen hex-nuts - 4 - by several turns.
• Loosen wiper arms - 2 - from the wiper axle by tilting slightly.
• Remove nuts completely and remove wiper arms.

Fig. 80: Removing Securing Clips And Cowl
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove securing clips - 1 - and remove cowl - 5 -.

Fig. 81: Removing Screws And Cover From E-Box In Plenum Chamber
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove cover for E-Box in plenum chamber, by removing the bolts - arrows -.

Fig. 82: Using Screwdriver To Remove Retainer Bar And Engine Control Module (ECM) J623
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Carefully pry off retainer bar with a screwdriver - arrow -.

Fig. 83: Removing Protective Housing From Engine Control Module (ECM) J623
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• To increase difficulty with which the ECM connectors can be accessed, the ECM - 1 - is secured in a metal housing - 5 - with retaining tabs - 2 - and shear bolts - 3 and 4 -.

Special tools, testers and auxiliary items required

Fig. 84: Heat Gun, Adapter Nozzle And Pliers
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Hot air gun - 1 - from the Wiring Harness Repair Kit VAS 1978A.
• Nozzle attachment - 2 - also from the Wiring Harness Repair Kit VAS 1978A
• Commercially available locking pliers (vise grips)

CAUTION:

To prevent damages (burning) of wire and harness connections, insulation and control modules, perform the following work procedures exactly! Observe operating instructions for heat gun.

Fig. 85: Removing Protective Housing From Engine Control Module (ECM) J623
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• The threads of the shear bolts - 4 - (that are not installed into the ECM) are coated with a locking compound. For this reason, the threads must be heated with the heat gun to remove both bolts.

Fig. 86: Removing Protective Housing From Engine Control Module (ECM) J623
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• The threads of both shear bolts - 3 - (that are installed into the ECM) are not coated with a locking compound. The threads in the ECM housing must not be heated and do not require to be heated (unintentional heating of the ECM).

Fig. 87: Performing Adjustments On Hot Air Gun
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Set adjustment on the heat gun as shown in the illustration, with the temperature potentiometer - 2 - set to maximum heat and the two-stage air flow switch - 3 - set to level 3.

NOTE:

Then, the shear bolts are heated with the heat gun. During this step, the holding effect that the locking compound has on the shear bolt threads is reduced, thereby allowing the shear bolts to be unscrewed easier. Cover all painted components to prevent damage that may be caused by the heat gun or the locking pliers.

CAUTION:

By heating the shear bolts, parts of the protective housing are heated intensely. Do not burn yourself on this! Make sure that only the shear bolts are heated as much as possible, and not any of the surrounding parts. Possibly cover these parts.

• Direct heat gun nozzle at shear bolt on the retaining tab.

Fig. 88: Using Heat Gun To Direct Heat Gun Nozzle At Shear Bolt Of Retaining Tab
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Switch on heat gun and heat bolt for approximately 20 to 25 seconds.

Fig. 89: Using Locking Pliers To Remove Shear Bolt
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Then grab bolt head with the locking pliers and unscrew the shear bolt.

The procedure for the second shear bolt is exactly the same.

• Both bolts that are installed into the ECM do not require heating. They can be removed without heat.

Then, the engine control module (ECM) can be separated from the protective housing.

Fig. 90: Disengaging Electrical Connector Retainers And Disconnecting Electrical Connectors From Engine Control Module (ECM) J623
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disengage connector retainers - arrows - and disconnect connectors - 1 and 2 - from Engine Control Module (ECM).
• Remove old ECM and install the new ECM.

Installing

Installation is in reverse order of removal, note the following:

• The Engine Control Module (ECM) J623 must be equipped with the metal retainer.
• Clean threaded holes for shear bolts of locking compound residue. Cleaning can be performed with a thread cutter (tap).
• Always use new shear bolts.

After installing a new Engine Control Module (ECM), the following work steps must be performed:

• Activate engine control module (ECM) in "Guided Functions" operating mode under "Replace ECM".

Heated Oxygen Sensor (HO2S) G39 and Oxygen Sensor (O2S) Heater Z19 before catalytic converter, removing and installing

Removing

Special tools, testers and auxiliary items required

Fig. 91: Identifying Ring Spanner 7-Piece Set 3337
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Ring Spanner 7-piece Set 3337

Fig. 92: Disconnecting 4-Pin Electrical Harness Connector From Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disconnect electrical harness connector - 1 - of the Heated Oxygen Sensor (HO2S) G39 and Oxygen Sensor (O2S) Heater Z19.

Fig. 93: Identifying Oxygen Sensors
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove Heated Oxygen Sensor (HO2S) G39 - 2 - using a tool from the Ring Spanner 7-piece Set 3337.

Installing

When installing, note the following:

NOTE:

New oxygen sensors are coated with assembly paste; the paste must not get into slots of oxygen sensor body. For a used oxygen sensor, only coat threads with hot bolt paste. This paste must not come into contact with sensor slots. Hot bolt paste Wiring connection of oxygen sensor must always be secured in the same position when installing so that contact with the exhaust pipe is avoided. Torque specification 55 Nm.

Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 and Oxygen Sensor (O2S) Heater 1 (behind Three Way Catalytic Converter (TWC)) Z29 , removing and installing

Removing

Special tools, testers and auxiliary items required

Fig. 94: Identifying Ring Spanner 7-Piece Set 3337
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Ring Spanner 7-piece Set 3337

Fig. 95: Disconnecting 4-Pin Electrical Harness Connector From Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disconnect electrical connector - 2 - (brown connector) on Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130.

Fig. 96: Identifying Oxygen Sensors
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 - 1 - using the tool from the Ring Spanner 7-piece Set 3337.

Installing

When installing, note the following:

NOTE:

New oxygen sensors are coated with assembly paste; the paste must not get into slots of oxygen sensor body. For a used oxygen sensor, only coat threads with hot bolt paste. This paste must not come into contact with sensor slots. Hot bolt Wiring connection of oxygen sensor must always be secured in the same position when installing so that contact with the exhaust pipe is avoided. Torque specification 55 Nm.

28 - Ignition/Glow plug System

Ignition system, checking

Ignition system, general information

• The engine control module is equipped with On Board Diagnostics (OBD).
• For the electric components to work properly, a voltage of at least 11.5 Volts is required.
• It is possible that the control module will recognize a malfunction and store a DTC during some tests. Therefore after completing all checks and repairs the DTC memory must be checked and if necessary erased.
• If the engine only starts briefly and then turns off again after troubleshooting, repair or checking of the components, it may be that the immobilizer is blocking the Engine Control Module (ECM). DTC memory must then be checked and if necessary, control module must be adapted.

Safety precautions

CAUTION:

Test and measuring equipment must always be secured to the rear seat and be operated from there by a second person. If test and measuring instruments are operated from the front passengers seat and the vehicle is involved in an accident, there is a possibility that the person sitting in this seat may receive serious injuries when the airbag is triggered.

To reduce the risk of personal injury and/or damage to the fuel injection and ignition system, always observe the following:

• Do not touch or remove ignition wires when engine is running or turning at starter speed.
• Always switch ignition off before disconnecting or reconnecting wires for the ignition system, including high voltage wiring and test leads.
• If engine is to be cranked at starting RPM without starting (e.g. for compression testing), disconnect connectors from ignition coils and from fuel injectors. After performing work, check and erase DTC memory.
• Cleaning the engine should only be performed with ignition switched off.

• The battery must only be disconnected and connected with the ignition switched off, since the Engine Control Module (ECM) can otherwise be damaged.

Technical data, Ignition

Engine data		2.0L/125 kW/147 kW/162 kW Turbo FSI engine
Idle speed Idle speed cannot be adjusted, it is regulated by idle stabilization		640 to 800 RPM
RPM limited by switching off fuel injectors and closing throttle valve		approx. 6500 RPM
Ignition timing is regulated by control module. It is not possible to adjust the ignition timing.
Ignition system		Single coil ignition system with 4 ignition coils (output stages integrated), that are connected directly to spark plugs via the ignition cables; The ignition coils can be pulled out of the cylinder head using Ignition Coil Puller T40039
Ignition sequence		1-3-4-2

Ignition system, assembly overview

Fig. 97: Ignition System, Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Knock Sensor (KS) 1 G61 and Knock Sensor (KS) 2 G66

• Contacts gold plated

2 - Ignition coil with power output stage (N70, N127, N291, N292)

• Removing and installing --> Ignition coils with power output stage, removing and installing
• To remove, use the ignition coil puller T40039

3 - Spark plug

• 30 Nm
• Removing and installing -->
  • 01 - MAINTENANCE
  • 01 - MAINTENANCE for MAINTENANCE PROCEDURES - CABRIOLET

4 - Bolt

• 20 Nm
• Tightening torque affects function of Knock Sensors (KS)

5 - Bolt

• 10 Nm

6 - Camshaft Position (CMP) sensor G40

• Contacts gold plated

7 - O-ring

• If damaged, replace O-ring

Ignition coils with power output stage, removing and installing

Special tools, testers and auxiliary items required

Fig. 98: Identifying Ignition Coil Puller T40039
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Ignition Coil Puller T40039

Removing:

Fig. 99: Removing Ignition Coils With Power Output Stage N70, N127, N291, N292 Electrical Harness Screws
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove both bolts - 1 - from the connector strip.

Fig. 100: Pulling All Ignition Coils Using Ignition Coil Puller T40039
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Pull all ignition coils approximately 30 mm out of spark plug shaft using Ignition Coil Puller T40039.

Fig. 101: Removing Ignition Coils With Power Output Stage N70, N127, N291, N292 Electrical Harness Screws
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Release connectors and pull all connectors simultaneously off from the ignition coils.

Installing:

• Insert all ignition coils loosely into spark plug shaft.

Fig. 102: Connecting Connectors To Ignition Coils
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Align ignition coils to the connectors and then connect all of the connectors onto the ignition coils.
• Press ignition coils uniformly onto the spark plugs by hand (do not use an impact tool).

Didn't find what you were looking for? Try to find in:
- ElsaWin online
- Alldata Online (Beta)