3.2L V6 4V FUEL INJECTION IGNITION, ENGINE CODE(S): BKH

• HEADINGS
  • 24 - Fuel injection system
    • Simos Fuel Injection System, Servicing
      • Safety precautions
      • Rules of cleanliness for performing work on fuel injection system
      • Procedure that must be performed before opening the high-pressure fuel injection system. Pay close attention!
      • Technical data
      • Component location, overview
        • Engine compartment, right side
        • Engine compartment, left side
        • Component location SIMOS Control Module J361
        • Location Throttle Position (TP) Sensor G79/Accelerator Pedal Position Sensor 2 G185
        • Installed location Brake light switch F/Brake pedal switch F47 , Clutch pedal switch F36
        • Clutch Pedal Starter Interlock Switch F194
        • Right holder for connectors on bulkhead
        • Left holder for connectors on bulkhead
        • Oxygen sensors location, cylinder bank 1 (right)
        • Oxygen sensors location, cylinder bank 2 (left)
        • Electrical connectors on right rear of engine
        • Electrical connectors on left rear of engine
        • Hall sensor and valve for camshaft adjustment, bank 1
        • Hall sensor and valve for camshaft adjustment, bank 2
        • Low Fuel Pressure Sensor G410 installation location
        • Component location front on engine
        • Component location on rear of intake manifold
        • Component location on the high pressure pump
        • Left Electro-Hydraulic Engine Mount Solenoid Valve N144 or Right Electro-Hydraulic Engine Mount Solenoid Valve N145 installation location
        • Component location under intake manifold, cylinder bank 1 (right)
        • Component location under intake manifold, cylinder bank 2 (left)
        • Location Engine Speed (RPM) Sensor G28
      • Air filter, component overview
      • Air filter element, removing and installing
      • Intake manifold upper-part, component overview
        • Installed location of tooth segments for variable intake manifold
      • Intake manifold upper-part, removing and installing
      • Intake manifold lower-part, component overview
      • Intake manifold lower-part with fuel rail, removing and installing
      • Fuel injectors, removing and installing
      • Fuel pressure and residual pressure before high pressure pump, checking
      • High pressure pump, removing and installing
      • Fuel system, bleeding
      • Wiring and components, checking with Test box V.A.G 1598/42
      • Engine Control Module (ECM), removing and installing
      • Oxygen sensor before catalytic converter, bank 1 (right side), removing and installing
      • Oxygen sensor before catalytic converter, bank 2 (left side), removing and installing
      • Oxygen sensor behind catalytic converter, bank 1 (right side), removing and installing
      • Oxygen sensor behind catalytic converter, bank 2 (left side), removing and installing
  • 28 - Ignition system
    • General information and safety measures
      • Ignition system, general information
      • Safety precautions
    • Ignition, servicing
      • Technical data
      • Ignition coils, removing and installing
• FIGURES
  • Fig. 1: Identifying Vehicle Diagnosis, Testing And Information System VAS 5051B
  • Fig. 2: Connecting Data Link Connector (DLC)
  • Fig. 3: Diagnostic System VAS 5051: Display
  • Fig. 4: Diagnostic System VAS 5051: Display
  • Fig. 5: VAS 5051 Tester Displaying Control Module Identification And Coding
  • Fig. 6: Diagnostic System VAS 5051: Display
  • Fig. 7: Diagnostic System VAS 5051: Display
  • Fig. 8: Diagnostic System VAS 5051: Display
  • Fig. 9: Diagnostic System VAS 5051: Display - Display Fields
  • Fig. 10: Engine Compartment, Right Side Component Location, Overview
  • Fig. 11: Engine Compartment, Left Side Component Location, Overview
  • Fig. 12: Component Location SIMOS Control Module J361
  • Fig. 13: Location Throttle Position (TP) Sensor G79/Accelerator Pedal Position Sensor 2 G185
  • Fig. 14: Installed Location Brake Light Switch F/Brake Pedal Switch F47 , Clutch Pedal Switch F36
  • Fig. 15: Installing and Adjusting Clutch Pedal Starter Interlock Switch F194
  • Fig. 16: Right Holder For Connectors On Bulkhead
  • Fig. 17: Left Holder For Connectors On Bulkhead
  • Fig. 18: Oxygen Sensors Location, Cylinder Bank 1 (Right)
  • Fig. 19: Removing Oxygen Sensor Using Ring Spanner Set 3337
  • Fig. 20: Electrical Connectors On Right Rear Of Engine
  • Fig. 21: Electrical Connectors On Left Rear Of Engine
  • Fig. 22: Disconnecting Electrical Harness Connectors
  • Fig. 23: Disconnecting Electrical Harness Connectors
  • Fig. 24: Low Fuel Pressure Sensor G410 Installation Location
  • Fig. 25: Component Location Front On Engine
  • Fig. 26: Identifying Electrical Harness Connectors
  • Fig. 27: Disconnecting Electrical Connector
  • Fig. 28: Left Electro-Hydraulic Engine Mount Solenoid Valve N144 Or Right Electro-Hydraulic Engine Mount Solenoid Valve N145 Installation Location
  • Fig. 29: Component Location Under Intake Manifold, Cylinder Bank 1 (Right)
  • Fig. 30: Component Location Under Intake Manifold, Cylinder Bank 2 (Left)
  • Fig. 31: Location Engine Speed (RPM) Sensor G28
  • Fig. 32: Air Filter, Component Overview
  • Fig. 33: Identifying Bolts & Air Duct
  • Fig. 34: Disconnecting Check Valve From Connection At Air Duct Hose
  • Fig. 35: Removing Upper Part Of Air Filter Housing
  • Fig. 36: Intake Manifold Upper-Part, Component Overview
  • Fig. 37: Installed Location Of Tooth Segments For Variable Intake Manifold
  • Fig. 38: Removing Rear Engine Cover
  • Fig. 39: Identifying Front Engine Cover
  • Fig. 40: Disconnecting Check Valve From Connection At Air Duct Hose
  • Fig. 41: Disconnecting Electrical Harness Connectors
  • Fig. 42: Identifying Electrical Harness Connectors
  • Fig. 43: Disconnecting Vacuum Hose
  • Fig. 44: Disconnecting Crankcase Breather Hose At Pressure Regulator Valve
  • Fig. 45: Removing Bolts And Intake Manifold Upper-Part
  • Fig. 46: Intake Manifold Lower-Part, Component Overview
  • Fig. 47: Identifying Special Tools - Intake Manifold Lower-Part With Fuel Rail, Removing And Installing
  • Fig. 48: Identifying Hand Vacuum Pump VAS 6213
  • Fig. 49: Removing High-Pressure Line, Thereby Removing Bolts And Union Nuts
  • Fig. 50: Removing/Installing Intake Manifold Bolts And Nuts
  • Fig. 51: Connecting Hand Vacuum Pump VAS 6213 To Intake Manifold Runner Control Vacuum Actuator
  • Fig. 52: Removing/Installing Intake Manifold Bolts And Nuts
  • Fig. 53: Removing High-Pressure Line, Thereby Removing Bolts And Union Nuts
  • Fig. 54: Fastening High-Pressure Line At Fuel Rail Using Torque Wrench V.A.G 1331 With Open End Wrench Socket V.A.G 1331/8
  • Fig. 55: Fastening High-Pressure Line At Fuel Rail Using Torque Wrench V.A.G 1331 With Open End Wrench Socket V.A.G 1331/2
  • Fig. 56: Fastening High-Pressure Line (14 mm) At High Pressure Pump Use Torque Wrench V.A.G 1331 With Ratchet V.A.G 1331/1 And Socket 14 mm 3150
  • Fig. 57: Fastening High-Pressure Line At High Pressure Pump Using Torque Wrench V.A.G 1331 With Ratchet V.A.G 1331/1 And Socket 17 mm T40055
  • Fig. 58: Identifying Tool Set T10133
  • Fig. 59: High-Pressure Fuel Injector - Component Overview
  • Fig. 60: Using Screwdriver To Bend Retaining Tabs Of Radial Adjustment Aside And Pull Support Ring From Fuel Injector
  • Fig. 61: Guiding Puller T10133/2 Into Groove On Fuel Injector And Carefully Drive Fuel Injector Out
  • Fig. 62: Cleaning Fuel Injector In Area Of Sealing Ring
  • Fig. 63: Cleaning Bore In Cylinder Head With Nylon Cylinder Brush T10133/4
  • Fig. 64: Installing Fuel Injector Again With Support Ring And Clipping In Radial Compensation On Support Ring
  • Fig. 65: Placing Assembly Cone T10133/5 With New Teflon Seal Onto Fuel Injector
  • Fig. 66: Sliding Combustion Chamber Seal As Far Possible Onto Assembly Cone T10133/5 Using Assembly Sleeve T10133/6
  • Fig. 67: Pressing Calibrating Sleeve T10133/7 On To Fuel Injector Until It Stops
  • Fig. 68: Pressing Calibrating Sleeve T10133/8 On To Fuel Injector Until It Stops
  • Fig. 69: Sliding Fuel Injector Into Bore Cylinder Head As Far As Stop Using Assembly Drift T10133/9
  • Fig. 70: Identifying Pressure Gauge V.A.G 1318
  • Fig. 71: Identifying Remote Control Connection V.A.G 1348/3A
  • Fig. 72: Unbolting Cover
  • Fig. 73: Disconnecting Electrical Harness Connector At Locking Flange
  • Fig. 74: Removing Cover Bolts For Locking Flange
  • Fig. 75: Disconnecting Electrical Harness Connector At Right Locking Flange
  • Fig. 76: Connecting Other End Of Hand Held Remote Starter (Jumper) To Vehicle Battery (+)
  • Fig. 77: Removing Rear Engine Cover
  • Fig. 78: Disconnecting Fuel Line
  • Fig. 79: Connecting Pressure Gauge V.A.G 1318 To Fuel Line Using Adapter V.A.G 1318/11 And V.A.G 1318/12
  • Fig. 80: Locating V.A.G 1318 Shut-Off Tap
  • Fig. 81: Identifying Special Tools - High Pressure Pump, Removing And Installing
  • Fig. 82: Removing Bolts & Union Nuts
  • Fig. 83: Removing Large Lifting Eye
  • Fig. 84: Disconnecting Electrical Connector
  • Fig. 85: Fastening High-Pressure Line (14 mm) At High Pressure Pump Use Torque Wrench V.A.G 1331 With Ratchet V.A.G 1331/1 And Socket 14 mm 3150
  • Fig. 86: Fastening High-Pressure Line At High Pressure Pump Using Torque Wrench V.A.G 1331 With Ratchet V.A.G 1331/1 And Socket 17 Mm T40055
  • Fig. 87: V.A.G 1598/39-1/2 Adapter Cables
  • Fig. 88: V.A.G 1598/42 Test Box
  • Fig. 89: 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. 90: 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. 91: Heat Gun, Adapter Nozzle And Pliers
  • Fig. 92: Removing Protective Housing From Engine Control Module (ECM) J623
  • Fig. 93: Identifying Plenum Chamber Cover & Removing Rubber Seal
  • Fig. 94: Removing Securing Clips And Cowl
  • Fig. 95: Removing Screws And Cover From E-Box In Plenum Chamber
  • Fig. 96: Using Screwdriver To Remove Retainer Bar And Engine Control Module (ECM) J623
  • Fig. 97: Performing Adjustments On Hot Air Gun
  • Fig. 98: Removing Protective Housing From Engine Control Module (ECM) J623
  • Fig. 99: Using Heat Gun To Direct Heat Gun Nozzle At Shear Bolt Of Retaining Tab
  • Fig. 100: Using Locking Pliers To Remove Shear Bolt
  • Fig. 101: Removing Protective Housing From Engine Control Module (ECM) J623
  • Fig. 102: Identifying Ring Spanner 7-Piece Set 3337
  • Fig. 103: Removing Rear Engine Cover
  • Fig. 104: Identifying Front Engine Cover
  • Fig. 105: Identifying Bolts & Air Duct
  • Fig. 106: Disconnecting Check Valve From Connection At Air Duct Hose
  • Fig. 107: Removing Upper Part Of Air Filter Housing
  • Fig. 108: Disconnecting Electrical Harness Connector For Heated Oxygen Sensor (HO2S) G39
  • Fig. 109: Removing Oxygen Sensor Using Ring Spanner Set 3337
  • Fig. 110: Identifying Ring Spanner 7-Piece Set 3337
  • Fig. 111: Removing Rear Engine Cover
  • Fig. 112: Removing Coolant Hoses At Coolant Expansion Tank
  • Fig. 113: Disconnecting Electrical Harness Connector For Heated Oxygen Sensor (HO2S) 2 G108
  • Fig. 114: Removing Oxygen Sensor Using Ring Spanner Set 3337
  • Fig. 115: Identifying Ring Spanner 7-Piece Set 3337
  • Fig. 116: Removing Rear Engine Cover
  • Fig. 117: Disconnecting Check Valve From Connection At Air Duct Hose
  • Fig. 118: Disconnecting Electrical Harness Connector For Heated Oxygen Sensor (HO2S) G39
  • Fig. 119: Removing Oxygen Sensor Using Ring Spanner Set 3337
  • Fig. 120: Identifying Ring Spanner 7-Piece Set 3337
  • Fig. 121: Removing Rear Engine Cover
  • Fig. 122: Removing Coolant Hoses At Coolant Expansion Tank
  • Fig. 123: Disconnecting Electrical Harness Connector For Heated Oxygen Sensor (HO2S) 2 G108
  • Fig. 124: Removing Oxygen Sensor Using Ring Spanner Set 3337
  • Fig. 125: Identifying Ignition Coil Puller T40039
  • Fig. 126: Identifying Front Engine Cover
  • Fig. 127: Removing Rear Engine Cover
  • Fig. 128: Identifying Bolts & Air Duct
  • Fig. 129: Disconnecting Check Valve From Connection At Air Duct Hose
  • Fig. 130: Disconnecting Electrical Connectors At Engine Coolant Temperature (ECT) Sensor G62 And Intake Manifold Flap Change-Over Valve N239
  • Fig. 131: Disconnecting Electrical Harness Connectors
  • Fig. 132: Removing Coolant Hoses At Coolant Expansion Tank
  • Fig. 133: Disconnecting Electrical Connectors On Intake Manifold Tuning (IMT) Valve Position Sensor G513
  • Fig. 134: Disconnecting Electrical Harness Connectors
  • Fig. 135: Removing Ignition Coils Using Ignition Coil Puller T40039
• TABLES

ENGINE PERFORMANCE

3.2 V6 4V Fuel Injection Ignition, Engine Code(s): BKH

24 - Fuel injection system

Simos Fuel Injection System, Servicing

Safety precautions

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

CAUTION:

Fuel system is under high pressure! Before opening high pressure components of the fuel injection system, pressure must be relieved to residual pressure --> Procedure that must be performed before opening the high-pressure fuel injection system. Pay close attention!. Then wrap a clean rag around the connection and relieve residual pressure by carefully loosening the connection.

• The ignition must be switched off before connecting or disconnecting injection and ignition system wiring or tester cables.
• It is possible that the control module will recognize a malfunction and store a DTC during some tests. Therefore, when all tests and repairs are completed, the DTC memory must be checked and, if necessary, erased. After DTC memory is erased, a readiness code must be generated for the engine control module using operating mode "Guided Fault-Finding".
• Clean engine only with the ignition switched off.

CAUTION:

The battery must only be disconnected and connected with the ignition switched off, since the Engine Control Module (ECM) can otherwise be damaged. Observe safety precautions when disconnecting the battery --> 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET .

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.

Rules of cleanliness for performing work on fuel injection 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. Do not use fluffy 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!

• The fuel injection system is separated into a high-pressure section (max. approx. 110 bar) and a low-pressure section (approx. 6 bar).
• Before opening the high-pressure section - e.g. removing high-pressure pump, fuel rail, fuel injectors, the motor for intake manifold runner control valve or any other component or fuel line that is located in the high-pressure section of the fuel injection system - the fuel pressure in the high-pressure section must be relieved to a residual pressure of approx. 8 bar. The procedure for this is as follows.

Special tools, testers and auxiliary items required

Fig. 1: Identifying Vehicle Diagnosis, Testing And Information System VAS 5051B
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Vehicle Diagnostic, Testing and Information System VAS 505 with Diagnostic Cable VAS 5051/5A (VAS 5051 B version shown as example only)

Work procedure

• Start engine and run at idle speed.

Fig. 2: Connecting Data Link Connector (DLC)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Connect Vehicle Diagnosis, Testing and Information System VAS 5051 with Diagnostic Cable VAS 5051/5A.

Fig. 3: Diagnostic System VAS 5051: Display
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Display on VAS 5051 :

• Click on Vehicle Self-Diagnosis button.

Fig. 4: Diagnostic System VAS 5051: Display
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Display on VAS 5051 :

• In selection - 1 - , press vehicle system "01 - Engine electronics".
• Wait until next display appears.

Fig. 5: VAS 5051 Tester Displaying Control Module Identification And Coding
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Display on VAS 5051 :

1 - Control module identification of engine control module (ECM)

• Click on --> button.

Fig. 6: Diagnostic System VAS 5051: Display
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Display on VAS 5051 :

1 - Selection of diagnostic functions

• In selection - 1 - , press diagnostic function "04- Basic Setting".

Fig. 7: Diagnostic System VAS 5051: Display
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Display on VAS 5051 :

• Select "140" in button field - 2 - for "display group 140" and confirm input by pressing Q button.

Fig. 8: Diagnostic System VAS 5051: Display
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Display on VAS 5051 :

Example:

1. 42%
2. 39.76 bar
3. 40.63 bar
4. Inactive

Fig. 9: Diagnostic System VAS 5051: Display - Display Fields
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Activate basic setting by pressing button A.

Display on VAS 5051 :

Example:

1. 0%
2. 0 bar
3. 5.46 bar
4. Lower

The fuel rail will continue to be filled with fuel, but it will no longer be under high pressure.

Now components or lines can be opened. A clean rag must be placed around the connection points. Escaping fuel must be absorbed.

• In operating mode "Guided Fault-Finding" , generate readiness code for engine control module (ECM).

Technical data

Engine code	BKH (3.2 l/4V/188 kW engine)
Idle speed 1)	650 to 750/min
Fuel pressure before high-pressure pump	approx. 6 bar positive pressure
Fuel pressure after high-pressure pump	approx. 35 bar positive pressure
1) Not adjustable.

Component location, overview

Engine compartment, right side

Fig. 10: Engine Compartment, Right Side Component Location, Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Right Electro-Hydraulic Engine Mount Solenoid Valve N145

• Only vehicles with automatic transmission
• Component location or under Left Electro-Hydraulic Engine Mount Solenoid Valve N144 or Right Electro-Hydraulic Engine Mount Solenoid Valve N145 installation location

2 - Camshaft position (CMP) sensor 3 G300

• Component location Hall sensor and valve for camshaft adjustment, bank 1

3 - Camshaft Adjustment Valve 1 N205

• Component location Hall sensor and valve for camshaft adjustment, bank 1

4 - Oxygen sensor G39

• Component location Oxygen sensors location, cylinder bank 1 (right)
• Connector location Right holder for connectors on bulkhead
• Removing and installing --> Oxygen sensor before catalytic converter, bank 1 (right side), removing and installing

5 - Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130

• Component location Oxygen sensors location, cylinder bank 1 (right)
• Connector location Right holder for connectors on bulkhead
• Removing and installing --> Oxygen sensor behind catalytic converter, bank 1 (right side), removing and installing

6 - Right holder for connectors

• Connector locations Right holder for connectors on bulkhead

7 - Low Fuel Pressure Sensor G410

• Component location --> Low Fuel Pressure Sensor G410 installation location

8 - Camshaft Adjustment Valve 1 (exhaust) N318

• Component location Hall sensor and valve for camshaft adjustment, bank 1

9 - Throttle valve control module J338

• After replacement, adapt in operating mode "Guided Fault-Finding" in "Adapting throttle valve control module"

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

11 - Intake Air Temperature (IAT) Sensor G42/Manifold Absolute Pressure (MAP) Sensor G71

• Component location Component location on rear of intake manifold

12 - Intake Manifold Runner Control (IMRC) Valve N316

Component location Component location on rear of intake manifold

13 - Knock sensor 1 G61

• Component location Component location under intake manifold, cylinder bank 1 (right)
• Connector location Electrical connectors on left rear of engine

14 - Intake Manifold Tuning (IMT) Valve Position Sensor G513

• Component location Component location front on engine

15 - Change-over valve for intake manifold flap N239

• Component location Component location front on engine

16 - Engine Coolant Temperature (ECT) Sensor G62

• Component location Component location front on engine

17 - Actuator for intake manifold change-over

18 - Intake Manifold Runner Position Sensor G336

• Component location Component location under intake manifold, cylinder bank 1 (right)
• After replacing, adapt in "Guided Fault Finding" operating mode under "Adapting intake manifold runner position sensor"

19 - Fuel injectors, Cylinder bank 1

• Cylinder 1 Fuel Injector N30
• Cylinder 2 Fuel Injector N31
• Cylinder 3 Fuel Injector N32
• Removing and installing --> Fuel injectors, removing and installing

20 - Camshaft Position (CMP) sensor G40

• Component location Hall sensor and valve for camshaft adjustment, bank 1

21 - Ignition coils, Cylinder bank 1

• Ignition Coil 1 with Power Output Stage N70
• Ignition Coil 2 with Power Output Stage N127
• Ignition Coil 3 with Power Output Stage N291
• Removing and installing --> Ignition coils, removing and installing

Engine compartment, left side

Fig. 11: Engine Compartment, Left Side Component Location, Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Fuel injectors, Cylinder bank 2

• Cylinder 4 Fuel Injector N33
• Cylinder 5 Fuel Injector N83
• Cylinder 6 Fuel Injector N84
• Removing and installing --> Fuel injectors, removing and installing

2 - Intake Manifold Runner Position Sensor 2 G512

• Component location Component location under intake manifold, cylinder bank 2 (left)
• After replacing, adapt in "Guided Fault-Finding" operating mode under "Adapting intake manifold runner position sensor"

3 - Engine speed (RPM) sensor G28

• Component location --> Location Engine Speed (RPM) Sensor G28

4 - Left holder for connectors

• Connector locations Left holder for connectors on bulkhead

5 - Instrument cluster

• With Malfunction Indicator Lamp (MIL) K83 and Electronic Power Control (EPC) Warning Lamp K132

6 - Throttle Position (TP) Sensor G79/Accelerator Pedal Position Sensor 2 G185

• In accelerator pedal module, component location --> Location Throttle Position (TP) Sensor G79/Accelerator Pedal Position Sensor 2 G185

7 - Brake light switch F/Brake pedal switch F47 and Clutch pedal switch F36

• Component location --> Installed location Brake light switch F/Brake pedal switch F47 , Clutch pedal switch F36

8 - Clutch Pedal Starter Interlock Switch F194

• Component location --> Clutch Pedal Starter Interlock Switch F194

9 - SIMOS Control Module J361

• Component location --> Component location SIMOS Control Module J361
• Removing and installing --> Engine Control Module (ECM), removing and installing
• After replacement, adapt throttle valve control module in operating mode "Guided Fault-Finding" in "Adapting throttle valve control module"
• After replacement on vehicles with automatic transmissions, also perform kick-down adaptation in the operating mode "Guided Fault-Finding" in "Kick-down adaptation"

10 - Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) G131

• Component location Oxygen sensors location, cylinder bank 2 (left)
• Connector location Left holder for connectors on bulkhead
• Removing and installing --> Oxygen sensor behind catalytic converter, bank 2 (left side), removing and installing

11 - Camshaft Adjustment Valve 2 N208

Component location Hall sensor and valve for camshaft adjustment, bank 2

12 - Heated Oxygen Sensor (HO2S) 2 G108

• Component location Oxygen sensors location, cylinder bank 2 (left)
• Connector location Left holder for connectors on bulkhead
• Removing and installing --> Oxygen sensor before catalytic converter, bank 2 (left side), removing and installing

13 - Camshaft Adjustment Valve 2 (exhaust) N319

• Component location Hall sensor and valve for camshaft adjustment, bank 2

14 - Camshaft position (CMP) sensor 4 G301

• Component location Hall sensor and valve for camshaft adjustment, bank 2

15 - Left Electro-Hydraulic Engine Mount Solenoid Valve N144

• Only vehicles with automatic transmission
• Component location or under Left Electro-Hydraulic Engine Mount Solenoid Valve N144 or Right Electro-Hydraulic Engine Mount Solenoid Valve N145 installation location

16 - Ignition coils, Cylinder bank 2

• Ignition Coil 4 with Power Output Stage N292
• Ignition Coil 5 with Power Output Stage N323
• Ignition Coil 6 with Power Output Stage N324
• Removing and installing --> Ignition coils, removing and installing

17 - Camshaft position (CMP) sensor 2 G163

• Component location Hall sensor and valve for camshaft adjustment, bank 2

18 - High pressure pump

• With Fuel Metering Valve N290
• Component location Component location on the high pressure pump

19 - Fuel Pressure Sensor G247

• Component location Component location under intake manifold, cylinder bank 2 (left)

20 - Knock sensor 2 G66

• Component location Component location under intake manifold, cylinder bank 2 (left)
• Connector location Electrical connectors on left rear of engine

Component location SIMOS Control Module J361

Fig. 12: Component Location SIMOS Control Module J361
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• In E-box, plenum chamber.

Location Throttle Position (TP) Sensor G79/Accelerator Pedal Position Sensor 2 G185

Fig. 13: Location Throttle Position (TP) Sensor G79/Accelerator Pedal Position Sensor 2 G185
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• In accelerator pedal module - arrow -.

NOTE:

The Throttle Position (TP) Sensor G79 and Accelerator Pedal Position Sensor 2 G185 are integrated in the gas pedal module and cannot be replaced individually.

Installed location Brake light switch F/Brake pedal switch F47 , Clutch pedal switch F36

Fig. 14: Installed Location Brake Light Switch F/Brake Pedal Switch F47 , Clutch Pedal Switch F36
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• On pedal bracket.

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.

Clutch Pedal Starter Interlock Switch F194

Fig. 15: Installing and Adjusting Clutch Pedal Starter Interlock Switch F194
Courtesy of VOLKSWAGEN UNITED STATES, INC.

2 - Clutch Pedal Starter Interlock Switch F194

Right holder for connectors on bulkhead

Fig. 16: Right Holder For Connectors On Bulkhead
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1. To Heated Oxygen Sensor (HO2S) G39
2. To Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130

Left holder for connectors on bulkhead

Fig. 17: Left Holder For Connectors On Bulkhead
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1. To Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) G131
2. To Heated Oxygen Sensor (HO2S) 2 G108

Oxygen sensors location, cylinder bank 1 (right)

Fig. 18: Oxygen Sensors Location, Cylinder Bank 1 (Right)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1. Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130
2. Oxygen sensor G39

Oxygen sensors location, cylinder bank 2 (left)

Fig. 19: Removing Oxygen Sensor Using Ring Spanner Set 3337
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1. Heated Oxygen Sensor (HO2S) 2 G108
2. Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) G131

Electrical connectors on right rear of engine

Fig. 20: Electrical Connectors On Right Rear Of Engine
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1. To fuel injectors, cylinder bank 1

NOTE:

- Arrow - indicates Ground (GND) point

Electrical connectors on left rear of engine

Fig. 21: Electrical Connectors On Left Rear Of Engine
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1. Green; to Knock Sensor (KS) 1 G61
2. Grey; to Knock sensor (KS) 2 G66
3. To cylinder bank 2 fuel injectors and to Fuel Pressure Sensor G247

NOTE:

- Arrow - indicates Ground (GND) point

Hall sensor and valve for camshaft adjustment, bank 1

Fig. 22: Disconnecting Electrical Harness Connectors
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1. Camshaft Adjustment Valve 1 (exhaust) N318
2. Valve 1 for camshaft adjustment N205
3. Camshaft Position (CMP) sensor G40
4. Intake Manifold Runner Position Sensor G336
5. Camshaft position (CMP) sensor 3 G300

NOTE:

Ignore - arrows -.

Hall sensor and valve for camshaft adjustment, bank 2

Fig. 23: Disconnecting Electrical Harness Connectors
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1. Camshaft position (CMP) sensor 2 G163
2. Camshaft Adjustment Valve 2 N208
3. Camshaft Adjustment Valve 2 (exhaust) N319
4. Camshaft position (CMP) sensor 4 G301

NOTE:

Ignore - arrows -.

Low Fuel Pressure Sensor G410 installation location

Fig. 24: Low Fuel Pressure Sensor G410 Installation Location
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• On right cylinder head - arrow -.

Component location front on engine

Fig. 25: Component Location Front On Engine
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1. Engine Coolant Temperature (ECT) Sensor G62
2. Change-over valve for intake manifold flap N239
3. Intake Manifold Tuning (IMT) Valve Position Sensor G513

Component location on rear of intake manifold

Fig. 26: Identifying Electrical Harness Connectors
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1. Camshaft Adjustment Valve N205
2. Throttle valve control module J338
3. Evaporative Emission (EVAP) Canister Purge Solenoid Valve N80
4. Intake Air Temperature (IAT) Sensor G42/Manifold Absolute Pressure (MAP) Sensor G71
5. Intake Manifold Runner Control (IMRC) Valve N316

Component location on the high pressure pump

Fig. 27: Disconnecting Electrical Connector
Courtesy of VOLKSWAGEN UNITED STATES, INC.

2 - Fuel Metering Valve N290

NOTE:

- 1 - not installed. Ignore - arrows -.

Left Electro-Hydraulic Engine Mount Solenoid Valve N144 or Right Electro-Hydraulic Engine Mount Solenoid Valve N145 installation location

Fig. 28: Left Electro-Hydraulic Engine Mount Solenoid Valve N144 Or Right Electro-Hydraulic Engine Mount Solenoid Valve N145 Installation Location
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Only for vehicles with automatic transmission: On left and right engine mounts - arrow -.

Component location under intake manifold, cylinder bank 1 (right)

Fig. 29: Component Location Under Intake Manifold, Cylinder Bank 1 (Right)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1. Intake Manifold Runner Position Sensor G336
2. Cylinder 1 Fuel Injector N30
3. Knock sensor 1 G61
4. Cylinder 2 Fuel Injector N31
5. Cylinder 3 Fuel Injector N32

Component location under intake manifold, cylinder bank 2 (left)

Fig. 30: Component Location Under Intake Manifold, Cylinder Bank 2 (Left)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1. Intake Manifold Runner Position Sensor 2 G512
2. Cylinder 6 Fuel Injector N84
3. Cylinder 5 Fuel Injector N83
4. Cylinder 4 Fuel Injector N33
5. Fuel Pressure Sensor G247
6. Knock sensor 2 G66

Location Engine Speed (RPM) Sensor G28

Fig. 31: Location Engine Speed (RPM) Sensor G28
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• At left front of transmission housing - arrow -.

Air filter, component overview

Fig. 32: Air Filter, Component Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - 1.5 Nm

2 - Air duct

• Clipped into lower part of air filter housing
• Clean air duct of dirt and leaves

3 - 1.5 Nm

4 - Air duct

• To lock carrier
• Clean air duct of dirt and leaves

5 - Air duct

• Clean air duct of dirt and leaves

6 - Strainer

7 - O-ring

• Replace

8 - Air duct hose to Throttle Valve Control Module J338

9 - Rubber grommet

10 - Spreader clip

11 - 1.5 Nm

12 - Upper part of air filter housing

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

13 - Air filter element

• Always use a genuine air filter element
• Removing and installing --> Air filter element, removing and installing
• Maintenance intervals

14 - Rubber grommet

15 - Lower part of air filter housing

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

Air filter element, removing and installing

Removing

Fig. 33: Identifying Bolts & Air Duct
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove bolts - arrows -.
• Remove air duct - 1 - and - 2 -.

Fig. 34: Disconnecting Check Valve From Connection At Air Duct Hose
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disconnect check valve - 1 - from air duct hose.
• Remove air duct hose, thereby loosening hose clamp - 2 - and opening clips - arrows -.

Fig. 35: Removing Upper Part Of Air Filter Housing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove bolts for upper part of air filter housing.
• Remove upper part of air filter housing.

NOTE:

Disregard - arrow -.

• Remove air filter element.

Installing

NOTE:

Always use an original equipment air filter element. Hose connections and hoses in intake area must be free of oil and grease before installing. When installing, do not use any lubricants containing silicone. Air filter housing must always be clean. Secure all hose connections using hose clamps appropriate for the model type . Note the following when blowing out air filter housing with compressed air: To prevent malfunctions, cover critical air-flow engine components such as air duct pipes, etc. with a clean cloth. Observe disposal regulations!

• Clean air filter housing (upper and lower sections) of salt residue, dirt or leaves (use vacuum cleaner if necessary).
• Check air duct hose (clean air side) for salt residue, dirt and leaves.
• Check intake ducting up to air filter element for dirt.
• Make sure that air filter element is properly centered when placed into mounting of 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. Pay attention to sealing lip of air filter element (false air).
• Then, fasten upper part of air filter housing to lower part of air filter housing.
• Further installation is performed in reverse order.

Intake manifold upper-part, component overview

Fig. 36: Intake Manifold Upper-Part, Component Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Intake Manifold Tuning (IMT) Valve Position Sensor G513

2 - 2.5 Nm

3 - 2.5 Nm

4 - Actuator for intake manifold change-over

• Installed location of tooth segments for variable intake manifold Installed location of tooth segments for variable intake manifold
• As replacement part together with - 24 -

5 - Seal

• Replace if damaged
• Lift out with screwdriver to replace
• Press in by hand

6 - Ball pin, 2.5 Nm

7 - Intake manifold upper part

• Removing and installing --> Intake manifold upper-part, removing and installing

8 - Throttle valve control module J338

9 - 5 Nm

10 - Wire harness retainer

11 - Seal

• Replace

12 - Intake Manifold Runner Control (IMRC) Valve N316

13 - 2.5 Nm

14 - Intake Air Temperature (IAT) Sensor G42/Manifold Absolute Pressure (MAP) Sensor G71

15 - O-ring

• Replace

16 - 2.5 Nm

17 - Crankcase housing ventilation pressure regulator valve

18 - O-ring

• Replace

19 - 6 Nm

20 - Washer

21 - Sleeve

22 - Seals

• Replace

23 - Seal

• Replace if damaged
• Lift out with screwdriver to replace
• Press in by hand

24 - Lever with tooth segment

• For variable intake manifold
• Installed location of tooth segments Installed location of tooth segments for variable intake manifold
• As replacement part together with - 4 -

25 - Seal

• Replace if damaged
• Lift out with screwdriver to replace
• Press in by hand

26 - Change-over valve for intake manifold flap N239

Installed location of tooth segments for variable intake manifold

Fig. 37: Installed Location Of Tooth Segments For Variable Intake Manifold
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• The lower edges of tooth segments must be flush with one another - arrows -.

Intake manifold upper-part, removing and installing

Removing

NOTE:

All cable ties which are opened or cut open when removing, must be replaced in the same position when installing.

Fig. 38: Removing Rear Engine Cover
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Pull rear engine cover off - arrows -.

Fig. 39: Identifying Front Engine Cover
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Pull front engine cover off - arrows -.

Fig. 40: Disconnecting Check Valve From Connection At Air Duct Hose
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disconnect check valve - 1 - from connection at air duct hose.
• Remove air duct hose, thereby loosening hose clamp - 2 - and opening clips - arrows -.

Fig. 41: Disconnecting Electrical Harness Connectors
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disconnect electrical harness connectors.

1. Intake Manifold Flap Change-over Valve N239
2. Intake Manifold Tuning (IMT) Valve Position Sensor G513

• Remove vacuum lines - arrow A - and - arrow B -.
• Disconnect vacuum hose - arrow C - at leak detection pump.

Fig. 42: Identifying Electrical Harness Connectors
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disconnect electrical harness connectors.

1. Camshaft Adjustment Valve 1 N205
2. Throttle valve control module J338
3. Evaporative Emission (EVAP) Canister Purge Solenoid Valve N80
4. Intake Air Temperature (IAT) Sensor G42/Manifold Absolute Pressure (MAP) Sensor G71
5. Intake Manifold Runner Control (IMRC) Valve N316

• Free up wiring harness.

Fig. 43: Disconnecting Vacuum Hose
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disconnect vacuum hoses - arrows -.
• Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 - 1 - from Throttle Valve Control Module J338.

Fig. 44: Disconnecting Crankcase Breather Hose At Pressure Regulator Valve
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disconnect crankcase breather hose at pressure regulator valve - arrow -.

NOTE:

To improve clarity, the removed engine is shown from the rear.

Fig. 45: Removing Bolts And Intake Manifold Upper-Part
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove bolts - arrows - and remove intake manifold upper-part.

NOTE:

Plug intake ports of the cylinder head with clean rags.

Installing

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

NOTE:

Replace gaskets and O-rings. During installation, all cable ties must be re-installed at the same location. Secure all hose connections using hose clamps appropriate for the model type .

Torque specifications

Component	Nm
Intake manifold upper-part to intake manifold lower-part	6 1)
Hose clamps 9 mm wide	3
1) Tighten diagonally in stages.

Intake manifold lower-part, component overview

Fig. 46: Intake Manifold Lower-Part, Component Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Intake manifold lower part

• Removing and installing --> Intake manifold lower-part with fuel rail, removing and installing
• After installation, adapt both intake manifold runner position sensors in operating mode "Guided Fault-Finding" in "Adapting intake manifold runner position sensor"

2 - Fuel rail

3 - Fuel Pressure Sensor G247

4 - High-pressure lines

CAUTION:

Before opening high pressure components of the fuel injection system, pressure must be relieved to residual pressure --> Procedure that must be performed before opening the high-pressure fuel injection system. Pay close attention!. Then wrap a clean rag around the connection and relieve residual pressure by carefully loosening the connection.

• Do not change bend shape
• Tighten high-pressure lines To fasten high-pressure line (14 mm) on fuel rail, use under Intake manifold lower-part with fuel rail, removing and installing

5 - 10 Nm

6 - Sleeve

7 - 10 Nm

8 - 2.5 Nm

9 - 10 Nm

10 - Retaining bracket for fuel rail

11 - Vacuum actuator for intake manifold runner control

12 - Vacuum hose

• To Intake Manifold Runner Control (IMRC) Valve N316

13 - 2.5 Nm

14 - Intake Manifold Runner Position Sensor

• Left Intake Manifold Runner Position Sensor 2 G512 , right Intake Manifold Runner Position Sensor G336

15 - 2.5 Nm

16 - Seal

• Replace if damaged
• Lift out with screwdriver to replace
• Press in by hand

17 - Seal

• Replace if damaged
• Lift out with screwdriver to replace
• Press in by hand

18 - Seals

• Replace

19 - Support ring

• Make sure it is seated properly
• The fuel rail wields force via support ring to hold fuel injector tightly in cylinder head.

20 - O-ring

• Replace
• Moisten with clean engine oil

21 - Spacer ring

• Replace if damaged

22 - Radial adjustment

• Replace if damaged
• Clip with support ring - 19 -

23 - Combustion chamber seal

• Replacing --> Fuel injectors, removing and installing.

24 - Fuel injector

Removing and installing --> Fuel injectors, removing and installing

Intake manifold lower-part with fuel rail, removing and installing

Fig. 47: Identifying Special Tools - Intake Manifold Lower-Part With Fuel Rail, Removing And Installing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools, testers and auxiliary items required

• Socket 14 mm 3150
• Torque wrench V.A.G 1331
• Ratchet V.A.G 1331/1
• Open end wrench socket 17 mm V.A.G 1331/2

• SW 14 socket, open ring V.A.G 1331/8
• Socket T40055

Special tools, testers and auxiliary items required

Fig. 48: Identifying Hand Vacuum Pump VAS 6213
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Hand vacuum pump VAS 6213

Removing

NOTE:

The following removal and installation procedure is for the left intake manifold lower-part. The procedure for the other side is identical.

CAUTION:

Fuel system is under high pressure! Before opening high pressure components of the fuel injection system, pressure must be relieved to residual pressure --> Procedure that must be performed before opening the high-pressure fuel injection system. Pay close attention!. Then wrap a clean rag around the connection and relieve residual pressure by carefully loosening the connection.

• Remove upper part of intake manifold --> Intake manifold upper-part, removing and installing.

Fig. 49: Removing High-Pressure Line, Thereby Removing Bolts And Union Nuts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove high-pressure line, thereby removing bolts and union nuts - 1 through 7 -.

Fig. 50: Removing/Installing Intake Manifold Bolts And Nuts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disconnect electrical harness connectors:

1. Intake Manifold Runner Position Sensor 2 G512
2. Fuel Pressure Sensor G247

• Remove bolts and nuts - arrows - and remove intake manifold lower-part with fuel rail.

NOTE:

Plug intake ports of the cylinder head with clean rags.

Installing

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

NOTE:

Replace gaskets and O-rings. Lightly moisten fuel injector O-rings with clean engine oil.

Fig. 51: Connecting Hand Vacuum Pump VAS 6213 To Intake Manifold Runner Control Vacuum Actuator
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Connect Hand Vacuum Pump VAS 6213 to intake manifold runner control vacuum actuator, as shown in illustration.
• Generate vacuum using hand vacuum pump.

• The intake flaps are opened.

NOTE:

If the intake flaps are not opened, they could have seized when installing the lower part of the intake manifold in the cylinder head.

• Install lower part of intake manifold and press fuel rail evenly onto fuel injectors.

Fig. 52: Removing/Installing Intake Manifold Bolts And Nuts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Fasten bolts - arrows - for intake manifold lower-part in a diagonal sequence and in stages.
• Remove hand vacuum pump from intake manifold runner control vacuum actuator.
• Connect electrical harness connectors - 1 - and - 2 -.

Fig. 53: Removing High-Pressure Line, Thereby Removing Bolts And Union Nuts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Hand-tighten union nuts - 1 - , - 4 - and - 7 - of high-pressure lines, and then for lines - 2 - , - 3 - , - 5 - and - 6 -.
• Make sure high-pressure lines are seated free of stress.

Fig. 54: Fastening High-Pressure Line At Fuel Rail Using Torque Wrench V.A.G 1331 With Open End Wrench Socket V.A.G 1331/8
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• To fasten high-pressure line (14 mm) on fuel rail, use Torque Wrench V.A.G 1331 with Socket Insert AF 14 V.A.G 1331/8.

Fig. 55: Fastening High-Pressure Line At Fuel Rail Using Torque Wrench V.A.G 1331 With Open End Wrench Socket V.A.G 1331/2
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• To fasten high-pressure line (17 mm) to fuel rail, use Torque Wrench V.A.G 1331 with Socket Insert AF 17 V.A.G 1331/2.

Fig. 56: Fastening High-Pressure Line (14 mm) At High Pressure Pump Use Torque Wrench V.A.G 1331 With Ratchet V.A.G 1331/1 And Socket 14 mm 3150
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• To fasten high-pressure line (14 mm) at high pressure pump use torque wrench V.A.G 1331 with ratchet V.A.G 1331/1 and socket 14 mm 3150.

Fig. 57: Fastening High-Pressure Line At High Pressure Pump Using Torque Wrench V.A.G 1331 With Ratchet V.A.G 1331/1 And Socket 17 mm T40055
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• To fasten high-pressure line (17 mm) to high pressure pump, use Torque Wrench V.A.G 1331 with Reversible Ratchet V.A.G 1331/1 and Socket T40055.

Torque specifications

Component		Nm
Intake manifold lower-part to cylinder head		9
High pressure lines to	High pressure pump	25
	Fuel rail	25

Fuel injectors, removing and installing

Special tools, testers and auxiliary items required

Fig. 58: Identifying Tool Set T10133
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Tool set T10133

Fig. 59: High-Pressure Fuel Injector - Component Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

High-pressure fuel injector - component overview

1. Radial adjustment - Replace if damaged
2. Combustion chamber seal (Teflon seal) - replace, the seal must not be greased or be handled with any other lubricant during installation
3. Groove on fuel injector
4. Spacer ring - Replace if damaged
5. O-ring - replace, lightly coat with clean engine oil during installation
6. Support ring - fuel rail wields force via support ring to hold fuel injector tightly in cylinder head

Removing

CAUTION:

Fuel system is under high pressure! Before opening high pressure components of the fuel injection system, pressure must be relieved to residual pressure --> Procedure that must be performed before opening the high-pressure fuel injection system. Pay close attention!. Then wrap a clean rag around the connection and relieve residual pressure by carefully loosening the connection.

• Remove upper part of intake manifold --> Intake manifold upper-part, removing and installing.
• Remove corresponding intake manifold lower-part --> Intake manifold lower-part with fuel rail, removing and installing.

If fuel injectors cannot be pulled out of cylinder head by hand, proceed as follows:

Fig. 60: Using Screwdriver To Bend Retaining Tabs Of Radial Adjustment Aside And Pull Support Ring From Fuel Injector
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Using a screwdriver, bend retaining tabs - 1 - of radial adjustment aside - arrow - and pull support ring - 2 - from fuel injector.

Fig. 61: Guiding Puller T10133/2 Into Groove On Fuel Injector And Carefully Drive Fuel Injector Out
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Attach slide wrench T10133/3 with adapter T10133/2.
• Guide puller T10133/2 into groove on fuel injector and carefully drive fuel injector out.

NOTE:

When setting the puller in place, the radial adjustment can be destroyed, because the retaining tabs break.

Fig. 62: Cleaning Fuel Injector In Area Of Sealing Ring
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Carefully remove old combustion chamber seal - arrow - , thereby cutting seal open with a knife or spreading seal open with a small screwdriver and pulling it forward and off.
• Make sure that the groove of the fuel injector does not become damaged. If groove is damage, the fuel injector must be replaced.

Installing

NOTE:

Replace combustion chamber seal and O-ring. Replace spacer ring if damaged. Lightly moisten fuel injector O-rings with clean engine oil. Re-insert injector lines at same cylinder.

Fig. 63: Cleaning Bore In Cylinder Head With Nylon Cylinder Brush T10133/4
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Clean bore in cylinder head with nylon cylinder brush T10133/4.

Fig. 64: Installing Fuel Injector Again With Support Ring And Clipping In Radial Compensation On Support Ring
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Clip radial adjustment - 1 - to support ring - 2 -.
• When re-installing a fuel injector, use a clean cloth to clean combustion residue from groove for combustion chamber seal and shaft of fuel injector.

Fig. 65: Placing Assembly Cone T10133/5 With New Teflon Seal Onto Fuel Injector
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Place assembly cone T10133/5 with new combustion chamber seal - 1 - on fuel injector - 2 -.

Fig. 66: Sliding Combustion Chamber Seal As Far Possible Onto Assembly Cone T10133/5 Using Assembly Sleeve T10133/6
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Slide combustion chamber seal as far possible onto assembly cone T10133/5 using assembly sleeve T10133/6.
• Turn assembly sleeve T10133/6 around and slide combustion chamber seal into groove.

NOTE:

When pushing the combustion chamber seal onto fuel injector, the seal spreads open. Therefore after pushing it on, it must be tightened again in 2 steps, as follows.

Fig. 67: Pressing Calibrating Sleeve T10133/7 On To Fuel Injector Until It Stops
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Press sizing sleeve T10133/7 with a slight turning motion (approx. 180°) onto fuel injector until it stops.
• Pull sizing sleeve T10133/7 off again, turning it in opposite direction.

Fig. 68: Pressing Calibrating Sleeve T10133/8 On To Fuel Injector Until It Stops
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Press sizing sleeve T10133/8 with a slight turning motion (approx. 180°) onto fuel injector until it stops.
• Pull sizing sleeve T10133/8 off again, turning it in opposite direction.
• Moisten new O-ring 3 with clean engine oil before installing.

NOTE:

The combustion chamber seal must not be oiled.

Fig. 69: Sliding Fuel Injector Into Bore Cylinder Head As Far As Stop Using Assembly Drift T10133/9
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Slide fuel injector into bore cylinder head as far as stop using assembly drift T10133/9.

NOTE:

The fuel injector must not be difficult to install. If necessary, wait as the combustion chamber seal continues to pull itself together.

• Make sure fuel injectors are correctly positioned in cylinder head.

• The electrical connection of fuel injector must engage in intended recess of cylinder head.

Further installation is in reverse order of removal, note the following:

• Install intake manifold lower-part --> Intake manifold lower-part with fuel rail, removing and installing.
• Install intake manifold upper-part --> Intake manifold upper-part, removing and installing.

Fuel pressure and residual pressure before high pressure pump, checking

Special tools, testers and auxiliary items required

Fig. 70: Identifying Pressure Gauge V.A.G 1318
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Pressure gauge K-Jetronic V.A.G 1318
• Pressure gauge adapter V.A.G 1318/10-12

Fig. 71: 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

Test conditions

• Battery voltage at least 12.5 V.
• Fuel filter OK.
• Fuel tank at least ¹ /₄ filled.
• Fuel Pump (FP) Control Module J538 OK; checking --> 20 - FUEL SUPPLY SYSTEM .

• Ignition switched off.

Checking fuel pressure

Sedan with front wheel drive:

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

Wagon with front wheel drive:

• 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 with front wheel drive:

• Fold forward right backrest of rear seat, if necessary.
• Remove luggage compartment floor trim.

Fig. 72: Unbolting Cover
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove cover for locking flange - arrows -.

Fig. 73: Disconnecting Electrical Harness Connector At Locking Flange
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Carefully release and disconnect electrical harness connector - arrow - at locking flange.

Vehicles with all wheel drive:

• Remove rear seat bench -->
  • 72 - SEAT - FRAMES
  • 72 - SEAT - FRAMES for BODY INTERIOR - CABRIOLET

Fig. 74: Removing Cover Bolts For Locking Flange
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove cover for right locking flange - arrows -.

Fig. 75: Disconnecting Electrical Harness Connector At Right Locking Flange
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Carefully release and disconnect electrical harness connector - arrow - at locking flange.

All:

Fig. 76: Connecting Other End Of Hand Held Remote Starter (Jumper) To Vehicle Battery (+)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Connect Remote Control V.A.G 1348/3A with adapter cable V.A.G 1348/3-3 with an adapter cable from Connector Test Set V.A.G 1594C at terminal - 1 -.
• Cover 2nd connector terminal of adapter cable V.A.G 1348/3-3 with insulating tape to prevent short circuit - arrow -.
• Route Remote Control V.A.G 1348/3A switch forward in engine compartment.
• Connect contact - 4 - to vehicle Ground (GND) using a self-made adapter cable.

• Connect alligator clip to battery "+".

Fig. 77: Removing Rear Engine Cover
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Pull rear engine cover off - arrows -.

CAUTION:

Fuel system is under high pressure! Before opening high pressure components of the fuel injection system, pressure must be relieved to residual pressure --> Procedure that must be performed before opening the high-pressure fuel injection system. Pay close attention!. Then wrap a clean rag around the connection and relieve residual pressure by carefully loosening the connection.

Fig. 78: Disconnecting Fuel Line
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disconnect fuel line - arrow -.

Fig. 79: Connecting Pressure Gauge V.A.G 1318 To Fuel Line Using Adapter V.A.G 1318/11 And V.A.G 1318/12
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Connect Fuel Inj. Pressure Gauge-CIS V.A.G 1318 with Adapter V.A.G 1318/11 and V.A.G 1318/12 in fuel line.
• Connect assisting hose - arrow - to pressure gauge and hold it in a measuring container.
• Open shut-off valve of pressure gauge. The lever points in direction of flow.
• Bleed fuel system, by briefly pressing remote control.

Fig. 80: Locating V.A.G 1318 Shut-Off Tap
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Close shut-off valve of pressure gauge. Lever stands perpendicular to direction of flow - arrow -.
• Hold switch of remote control until no more pressure increase is observed on fuel pressure gauge.

• Specified value: approx. 6 bar positive pressure

If specification is not obtained:

• Check delivery quantity of Fuel Pump (FP) --> 20 - FUEL SUPPLY SYSTEM .

Checking residual pressure

• Check for leaks and for residual pressure by observing pressure loss on pressure gauge.

• 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 and fuel line for leaks.
• Check pressure gauge for leaks.
• Check fuel lines and their connections for leaks.
• Replace fuel filter with integrated fuel pressure regulator --> 20 - FUEL SUPPLY SYSTEM .

• Replace fuel pump --> 20 - FUEL SUPPLY SYSTEM .

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

NOTE:

Before disconnecting pressure gauge, release pressure by opening shut-off valve. Hold a container in front of connection for this.

Torque specifications

Component	Nm
Fuel line to fuel rail	28

High pressure pump, removing and installing

Fig. 81: Identifying Special Tools - High Pressure Pump, Removing And Installing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools, testers and auxiliary items required

• Socket 14 mm 3150
• Torque wrench V.A.G 1331
• Ratchet V.A.G 1331/1
• Socket T40055

Removing

CAUTION:

Fuel system is under high pressure! Before opening high pressure components of the fuel injection system, pressure must be relieved to residual pressure --> Procedure that must be performed before opening the high-pressure fuel injection system. Pay close attention!. Then wrap a clean rag around the connection and relieve residual pressure by carefully loosening the connection.

• Drain coolant --> 19 - ENGINE - COOLING SYSTEM .
• Remove front coolant pipe --> 19 - ENGINE - COOLING SYSTEM .
• Remove upper part of intake manifold --> Intake manifold upper-part, removing and installing.

Fig. 82: Removing Bolts & Union Nuts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove bolts - 1 through 4 - and - 7 -.
• Loosen union nuts - 5 - and - 6 -.

Fig. 83: Removing Large Lifting Eye
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• If equipped, remove large lifting eye - arrows -.

Fig. 84: Disconnecting Electrical Connector
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disconnect electrical connector - 2 -.

NOTE:

Ignore - 1 -.

• Remove bolts - arrows -.
• Carefully lift high pressure lines.

NOTE:

Do not change bend shape.

• Remove high pressure pump with actuator.

Installing

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

NOTE:

Replace O-ring.

• To set high pressure pump in place, lift high pressure lines only slightly.

NOTE:

High pressure line connections must not show any signs of damage. Do not change bend shape of high pressure lines.

• Place high pressure pump with actuator into cylinder head and fasten.
• Hand-tighten union nuts for high-pressure lines.
• Make sure high-pressure lines are seated free of stress.

Fig. 85: Fastening High-Pressure Line (14 mm) At High Pressure Pump Use Torque Wrench V.A.G 1331 With Ratchet V.A.G 1331/1 And Socket 14 mm 3150
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• To fasten high-pressure line (14 mm) at high pressure pump use torque wrench V.A.G 1331 with ratchet V.A.G 1331/1 and socket 14 mm 3150.

Fig. 86: Fastening High-Pressure Line At High Pressure Pump Using Torque Wrench V.A.G 1331 With Ratchet V.A.G 1331/1 And Socket 17 Mm T40055
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• To fasten high-pressure line (17 mm) to high pressure pump, use Torque Wrench V.A.G 1331 with Reversible Ratchet V.A.G 1331/1 and Socket T40055.
• Install intake manifold upper-part --> Intake manifold upper-part, removing and installing.
• Install front coolant pipe --> 19 - ENGINE - COOLING SYSTEM .
• Fill with coolant --> 19 - ENGINE - COOLING SYSTEM .

Torque specifications

Component	Nm
High pressure pump to cylinder head	10
High pressure lines to high pressure pump	25

Fuel system, bleeding

To prevent damage to catalytic converter the fuel system must be bled after repair work on fuel lines or on fuel filter.

Work procedure

• Start engine and let engine run a few minutes at average RPM and then turn off again.

NOTE:

At the beginning, engine may run roughly due to air in fuel supply system.

• Check fuel supply system for leaks.
• Check DTC memory and, if necessary, erase.
• Then perform a road test with at least one acceleration at Wide Open Throttle (WOT), then fuel supply system must be checked again for leaks.
• Check DTC memory and, if necessary, erase it. After DTC memory is erased, a readiness code must be generated for engine control module using operating mode "Guided Fault-Finding".

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

Special tools, testers and auxiliary items required

Fig. 87: V.A.G 1598/39-1/2 Adapter Cables
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Adapter cable V.A.G 1598/39

Fig. 88: V.A.G 1598/42 Test Box
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Test box V.A.G 1598/42

Fig. 89: 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.

NOTE:

The test box V.A.G 1598/42 is designed with 105 terminals. It can be connected to the engine control module (ECM) via 2 different adapter cables. The engine control module (ECM) is connected to the vehicle electrical harness via a 60-pin connector and a 94-pin connector. For testing at the 60-pin connector, the adapter cable V.A.G 1598/39-1 is connected to the test box with connector "A". Components of the 60-pin harness connection --> Electrical Wiring Diagrams, Troubleshooting and Component Locations. For testing at the 94-pin connector, the adapter cable V.A.G 1598/39-2 is connected to the test box with connectors "A" and "B". Components of the 94-pin harness connection --> Electrical Wiring Diagrams, Troubleshooting and Component Locations. 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 procedure will indicate whether the engine control module is to remain connected to the test box or not. To connect measuring instruments (e.g. Voltage Tester V.A.G 1527B , Multimeter V.A.G 1526C etc.) always use Connector Test Set V.A.G 1594C.

The engine control module (ECM) must be removed to disconnect the ECM harness connectors --> Engine Control Module (ECM), removing and installing.

CAUTION:

To avoid damaging electronic components, set measuring range before connecting test leads and observe all test requirements.

Fig. 90: 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.

• Connect Test Box V.A.G 1598/42 to wiring harness with adapter lead V.A.G 1598/39-1 or adapter lead V.A.G 1598/39-2. Clamp test box Ground (GND) clip to battery negative terminal. The procedure will indicate whether engine control module is to be connected to test box or not.
• Perform test as described in corresponding repair procedure.
• After completing test, install engine control module (ECM) --> Engine Control Module (ECM), removing and installing.

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

• Check DTC memory and, if necessary, erase it. After DTC memory is erased, a readiness code must be generated for engine control module using operating mode "Guided Fault-Finding".

Engine Control Module (ECM), removing and installing

Special tools, testers and auxiliary items required

Fig. 91: Heat Gun, Adapter Nozzle And Pliers
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Heat Gun 220 V/50 Hz VAS 1978/14 - 1 - with nozzle attachment - 2 - from Wiring Harness Repair kit VAS 1978A
• Locking pliers - 3 - (commercially available)

Fig. 92: Removing Protective Housing From Engine Control Module (ECM) J623
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

The Engine Control Module (ECM) - 1 - is bolted to a protective housing - 5 -. To make removal of shear bolts - 4 - for retaining tabs - 2 - more difficult, the threads are coated with locking compound. To disconnect the connectors from the engine control module (ECM) (e.g. to connect the test box or to replace the ECM), the protective housing must be removed.

Removing

• If engine control module (ECM) was replaced, select diagnostic object "Replacing engine control module (ECM)" in "Guided Fault-Finding".
• Turn ignition and remove ignition key.

Fig. 93: Identifying Plenum Chamber Cover & Removing Rubber Seal
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove rubber seal of plenum chamber cover in direction of - arrow -.
• Remove plenum chamber cover - 1 - toward front.

Fig. 94: Removing Securing Clips And Cowl
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Pry off both covers - 3 - using a screwdriver.
• Loosen hex-nuts - 4 - by several turns.
• Loosen wiper arms - 2 - from wiper axle by tilting slightly.
• Remove nuts completely and remove wiper arms.

NOTE:

If wiper arm cannot be removed in this way, use a standard puller.

• Disconnect securing clips - 1 - and remove cowl grille - 5 -.

Fig. 95: Removing Screws And Cover From E-Box In Plenum Chamber
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove cover for E-Box in plenum chamber - arrows -.

Fig. 96: Using Screwdriver To Remove Retainer Bar And Engine Control Module (ECM) J623
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Using a screwdriver, carefully pry off mounting bracket - arrows - and remove Engine Control Module (ECM) from E-Box.

NOTE:

Engine Control Module (ECM) remains connected at wiring harness.

CAUTION:

To avoid damage (burning) of wire connections and harness connectors, insulation and control modules, the following work steps must be adhered to exactly! Observe operating instructions for heat gun.

Fig. 97: Performing Adjustments On Hot Air Gun
Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

NOTE:

Next, the threads of the protective housing in which the shear bolts are threaded is heated using the heat gun. This step decreases the locking effect of the locking compound on the shear bolt thread, thus allowing the shear bolts to be removed more easily.

CAUTION:

By heating the shear bolts, parts of the protective housing will become extremely hot. Do not burn yourself on this! Ensure only the shear bolts are heated and not any of the surrounding parts. Possibly cover these parts.

Fig. 98: Removing Protective Housing From Engine Control Module (ECM) J623
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Perform the following steps in order on both shear bolts - 4 -.

Fig. 99: Using Heat Gun To Direct Heat Gun Nozzle At Shear Bolt Of Retaining Tab
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Direct heat gun nozzle at protective housing shear bolts.
• Switch heat gun on and heat bolt for approx. 20 to 25 seconds.

Fig. 100: Using Locking Pliers To Remove Shear Bolt
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove shear bolts with locking pliers - arrow -.

Fig. 101: Removing Protective Housing From Engine Control Module (ECM) J623
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

The threads of both shear bolts - 3 - that are installed in 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).

• Remove both shear bolts - 3 -.
• Separate retaining tab - 2 - of control module connector.
• Release and disconnect connectors from engine control module (ECM).

NOTE:

Adaptation values are erased when connectors are disconnected from Engine Control Module (ECM), DTC memory content remains intact.

Installing

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

• The ECM must be equipped with protective housing again.
• Clean locking compound residue from shear bolt threaded holes. Cleaning can be performed with a thread cutter (tap).
• 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 Fault-Finding" under "Replacing engine control module (ECM)".

Oxygen sensor before catalytic converter, bank 1 (right side), removing and installing

Special tools, testers and auxiliary items required

Fig. 102: Identifying Ring Spanner 7-Piece Set 3337
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Ring spanner 7-piece set for oxygen sensor 3337

Removing

Fig. 103: Removing Rear Engine Cover
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove rear engine cover - arrows -.

Fig. 104: Identifying Front Engine Cover
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove front engine cover - arrows -.

Fig. 105: Identifying Bolts & Air Duct
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove bolts - arrows -.
• Remove air duct - 1 - and - 2 -.

Fig. 106: Disconnecting Check Valve From Connection At Air Duct Hose
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disconnect check valve - 1 - from air duct hose.
• Remove air duct hose, thereby loosening hose clamp - 2 - and opening clips - arrows -.

Fig. 107: Removing Upper Part Of Air Filter Housing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove pin from spreader clips - arrow -.
• Remove air filter housing.

Fig. 108: Disconnecting Electrical Harness Connector For Heated Oxygen Sensor (HO2S) G39
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disconnect electrical harness connector - 1 - for Heated Oxygen Sensor (HO2S) G39 and free up wire.

NOTE:

Ignore - 2 -.

Fig. 109: Removing Oxygen Sensor Using Ring Spanner Set 3337
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove oxygen sensor - 2 - using ring spanner set 3337.

NOTE:

To improve clarity, the engine is removed.

Installing

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

NOTE:

New oxygen sensors are coated with assembly paste; the paste must not get into slots of oxygen sensor body. When reinstalling the previously used oxygen sensor, coat thread with hot bolt paste . Paste must not get on to slits of sensor body. Electrical wire of oxygen sensor must always be secured in the same position when installing so that contact with the exhaust pipe is avoided.

Torque specifications

Component	Nm
Oxygen sensor in front exhaust pipe	55

Oxygen sensor before catalytic converter, bank 2 (left side), removing and installing

Special tools, testers and auxiliary items required

Fig. 110: Identifying Ring Spanner 7-Piece Set 3337
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Ring spanner 7-piece set for oxygen sensor 3337

Removing

NOTE:

All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.

Fig. 111: Removing Rear Engine Cover
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove rear engine cover - arrows -.

Fig. 112: Removing Coolant Hoses At Coolant Expansion Tank
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove coolant expansion tank - arrow -.
• Disconnect electrical connection from Engine Coolant Level (ECL) Warning Switch F66 at bottom of coolant reservoir and set aside coolant reservoir with coolant hoses - 1 - and - 2 - connected.

Fig. 113: Disconnecting Electrical Harness Connector For Heated Oxygen Sensor (HO2S) 2 G108
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disconnect electrical harness connector - 2 - for Heated Oxygen Sensor (HO2S) 2 G108 and free up wire.

NOTE:

Ignore - 1 -.

Fig. 114: Removing Oxygen Sensor Using Ring Spanner Set 3337
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove oxygen sensor - 1 - using ring spanner set 3337.

NOTE:

To improve clarity, the engine is removed.

Installing

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

NOTE:

New oxygen sensors are coated with assembly paste; the paste must not get into slots of oxygen sensor body. When reinstalling the previously used oxygen sensor, coat thread with hot bolt paste . Paste must not get on to slits of sensor body. During installation, all cable ties must be re-installed at the same location. Wires of oxygen sensors must always be secured in the same position when installing so that contact with the exhaust pipe is avoided.

Torque specifications

Component	Nm
Oxygen sensor in front exhaust pipe	55

Oxygen sensor behind catalytic converter, bank 1 (right side), removing and installing

Special tools, testers and auxiliary items required

Fig. 115: Identifying Ring Spanner 7-Piece Set 3337
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Ring spanner 7-piece set for oxygen sensor 3337

Removing

NOTE:

All cable ties which are opened or cut open when removing, must be replaced in the same position when installing.

Fig. 116: Removing Rear Engine Cover
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove rear engine cover - arrows -.

Fig. 117: Disconnecting Check Valve From Connection At Air Duct Hose
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disconnect check valve - 1 - from connection at air duct hose.
• Remove air duct hose, thereby loosening hose clamp - 2 - and opening clips - arrows -.

Fig. 118: Disconnecting Electrical Harness Connector For Heated Oxygen Sensor (HO2S) G39
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disconnect electrical harness connector - 2 - for Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 and free up the wiring.

NOTE:

Ignore - 1 -.

Fig. 119: Removing Oxygen Sensor Using Ring Spanner Set 3337
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove oxygen sensor - 1 - using ring spanner set 3337.

NOTE:

To improve clarity, the engine is removed.

Installing

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

NOTE:

Replace O-ring. New oxygen sensors are coated with assembly paste; the paste must not get into slots of oxygen sensor body. When reinstalling the previously used oxygen sensor, coat thread with hot bolt paste . Paste must not get on to slits of sensor body. During installation, all cable ties must be re-installed at the same location. Electrical wire of oxygen sensor must always be secured in the same position when installing so that contact with the exhaust pipe is avoided.

Torque specifications

Component		Nm
Oxygen sensor in front exhaust pipe		55

Oxygen sensor behind catalytic converter, bank 2 (left side), removing and installing

Special tools, testers and auxiliary items required

Fig. 120: Identifying Ring Spanner 7-Piece Set 3337
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Ring spanner 7-piece set for oxygen sensor 3337

Removing

NOTE:

All cable ties which are opened or cut open when removing, must be replaced in the same position when installing.

Fig. 121: Removing Rear Engine Cover
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove rear engine cover - arrows -.

Fig. 122: Removing Coolant Hoses At Coolant Expansion Tank
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove coolant expansion tank - arrow -.
• Disconnect electrical connection from Engine Coolant Level (ECL) Warning Switch F66 at bottom of coolant reservoir and set aside coolant reservoir with coolant hoses - 1 - and - 2 - connected.

Fig. 123: Disconnecting Electrical Harness Connector For Heated Oxygen Sensor (HO2S) 2 G108
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disconnect electrical harness connector - 1 - for Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) G131 and free up wiring.

NOTE:

Ignore - 2 -.

Fig. 124: Removing Oxygen Sensor Using Ring Spanner Set 3337
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove oxygen sensor - 2 - using ring spanner set 3337.

NOTE:

To improve clarity, the engine is removed.

Installing

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

NOTE:

Replace O-ring. New oxygen sensors are coated with assembly paste; the paste must not get into slots of oxygen sensor body. When reinstalling the previously used oxygen sensor, coat thread with hot bolt paste . Paste must not get on to slits of sensor body. During installation, all cable ties must be re-installed at the same location. Electrical wire of oxygen sensor must always be secured in the same position when installing so that contact with the exhaust pipe is avoided.

Torque specifications

Component	Nm
Oxygen sensor in front exhaust pipe	55

28 - Ignition system

General information and safety measures

Ignition system, general information

• For trouble-free operation of the electrical components a voltage of at least 12.5 V is necessary.
• 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

If special testing equipment is required during road test, note the following:

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. Do not touch or disconnect wires of ignition system when engine is running or turning at starting RPM. Always switch ignition off before disconnecting or reconnecting wires for the injection and ignition system, including high voltage wiring and test leads.

CAUTION:

To reduce the risk of damage to the fuel injection and ignition system, always observe the following: If the engine is to be cranked at starting RPM without starting (e.g. during compression test), disconnect electrical connectors on ignition coils and on fuel injectors. After performing work, check and erase DTC memory. Clean engine only with the 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. Observe safety precautions when disconnecting the battery --> 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET .

Ignition, servicing

Technical data

Engine code		BKH (3.2 l/4V/188 kW engine)
Engine idle speed		650 to 750 RPM (not adjustable)
Ignition timing		Not adjustable, regulated by control module
Ignition system		Single coil ignition system with 6 ignition coils (power output stages integrated) that are inserted directly on spark plugs.
Spark plugs		Designations Data sheets for exhaust emission test Torque specification
Ignition sequence		1-5-3-6-2-4

Ignition coils, removing and installing

Special tools, testers and auxiliary items required

Fig. 125: Identifying Ignition Coil Puller T40039
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Puller T40039

Removing

Fig. 126: Identifying Front Engine Cover
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove front engine cover - arrows -.

Fig. 127: Removing Rear Engine Cover
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove rear engine cover - arrows -.

Cylinder bank 1 (right):

Fig. 128: Identifying Bolts & Air Duct
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove bolts - arrows -.
• Remove air duct - 1 - and - 2 -.

Fig. 129: Disconnecting Check Valve From Connection At Air Duct Hose
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disconnect check valve - 1 - from air duct hose.
• Remove air duct hose, thereby loosening hose clamp - 2 - and opening clips - arrows -.

Fig. 130: Disconnecting Electrical Connectors At Engine Coolant Temperature (ECT) Sensor G62 And Intake Manifold Flap Change-Over Valve N239
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disconnect electrical connectors at Engine Coolant Temperature (ECT) Sensor G62 - 1 - and Intake Manifold Flap Change-over Valve N239 - 2 -.

NOTE:

Ignore - 3 -.

Fig. 131: Disconnecting Electrical Harness Connectors
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disconnect electrical harness connectors.

1. Camshaft Adjustment Valve 1 (exhaust) N318
2. Camshaft Adjustment Valve 1 N205
3. Camshaft Position (CMP) sensor G40
4. Intake Manifold Runner Position Sensor G336
5. Camshaft position (CMP) sensor 3 G300

• Remove bolts - arrows - and disconnect electrical connections at ignition coils.
• Set electrical wiring harness aside.

Cylinder bank 2 (left):

Fig. 132: Removing Coolant Hoses At Coolant Expansion Tank
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove coolant expansion tank - arrow -.
• Disconnect electrical connection from Engine Coolant Level (ECL) Warning Switch F66 at bottom of coolant reservoir and set aside coolant reservoir with coolant hoses - 1 - and - 2 - connected.

Fig. 133: Disconnecting Electrical Connectors On Intake Manifold Tuning (IMT) Valve Position Sensor G513
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disconnect electrical connectors on Intake Manifold Tuning (IMT) Valve Position Sensor G513 - 1 -.

NOTE:

Ignore - 2 -.

Fig. 134: Disconnecting Electrical Harness Connectors
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disconnect electrical harness connectors.

1. Camshaft position (CMP) sensor 2 G163
2. Camshaft Adjustment Valve 2 N208
3. Camshaft Adjustment Valve 2 (exhaust) N319
4. Camshaft position (CMP) sensor 4 G301

• Remove bolts - arrows - and disconnect electrical connections at ignition coils.
• Set electrical wiring harness aside.

Continued for both sides:

Fig. 135: Removing Ignition Coils Using Ignition Coil Puller T40039
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove ignition coils using ignition coil puller T40039.

Installing

Installation is in reverse order of removal.

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