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4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
10 - Air flow control flaps
11 - Seal
❑ Renew
12 - Intake manifold
13 - Vacuum unit for air flow control flaps
❑ Checking ⇒ page 496
14 - Throttle valve module - J338- , throttle valve drive for electric throttle operation - G186-
❑ Throttle valve drive angle sender 1 for electric throttle - G187- and throttle valve drive angle sender 2 for
electric throttle - G188-
❑ After renewing throttle valve module - J338- it must be reprogrammed to engine control unit - J623-
⇒ Vehicle diagnostic tester via “Guided Functions”
15 - Bolts for intake manifold
❑ Pre-tighten to 3 Nm and tighten to 9 Nm
16 - Intake manifold flap potentiometer - G336-
17 - Fuel pressure sender - G247-
❑ 27 Nm
❑ Lubricate thread with clean engine oil
❑ Checking ⇒ page 493
❑ Removing and installing ⇒ page 486
Other specified torques
Further specified torques can be found at end of chapter entitled
“Disconnecting fuel rail from intake manifold” ⇒ page 480 .
2.9
Removing and installing intake manifold
with fuel rail
If intake manifold is renewed, intake manifold flap potentiometer
- G336- must be adapted to engine control unit - J623- using a
vehicle diagnostic tester .
2. Injection system
473
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4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
Special tools and workshop
equipment required
♦ Bit - T10347-
♦ Oil filter tool - 3417-
♦ Torque wrench - V.A.G 1331-
Note
♦ Observe all relevant safety precautions ⇒ page 278 .
♦ Observe rules for cleanliness ⇒ page 280 .
♦ The injectors can only be accessed after removal of the intake
manifold and fuel rail with air flow control flap.
♦ Combustion chamber ring seal (Teflon) and O-ring must al‐
ways be renewed.
♦ Assembly overview - intake manifold ⇒ page 469 .
♦ Assembly overview - fuel rail ⇒ page 472
474
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4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
Removing
– Only vehicles with sound generator: Remove charge air duct
to sound generator ⇒ page 455 .
– Remove engine cover panel ⇒ page 141 .
– Clean joint between intake manifold and cylinder head.
– Remove air filter housing ⇒ page 467 .
Golf, Eos, Scirocco:
– Remove radiator cowl ⇒ page 273 .
All:
– Disconnect vacuum line -arrow- to activated charcoal filter.
– Disconnect the following electrical connectors:
♦ Intake air temperature sender - G42- -1-
♦ Throttle valve module - J338- -2-
♦ Activated charcoal filter solenoid valve 1 - N80-
♦ Hall sender - G40-
– Disconnect vacuum line -1- at connecting point -2- and remove
the crankcase breather hose -3-.
– Unscrew bolts -arrows- for fuel supply pipe and lay pipe to
side.
2. Injection system
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WARNING
The fuel system is pressurised.
Danger of injury caused by fuel spray.
♦ Wear protective goggles.
♦ Wear protective gloves.
♦ To release pressure, wrap a clean cloth around the con‐
nection and carefully loosen the connection.
– Unscrew fuel pipe union nut -lower arrow-.
– Pull vacuum pipe -arrow- from intake manifold flap valve -
N316- .
– Unscrew coolant line bolts -arrows- from intake manifold.
– Pull electrical connector -1- from fuel pressure sender -
G247- .
476
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4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
– Release hose clip -2-.
– Unscrew bolt -4-.
– Separate electrical connector -arrow-.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Noise insulation .
– Remove charge air hose -A- and seal charge air cooler with a
clean cloth.
– Remove bolt -1- and take out air pipe downwards.
– Unbolt bracket from intake manifold -arrows-.
2. Injection system
477
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– Remove throttle valve module - J338- -arrows-.
– Remove intake manifold support; to do this, unscrew securing
nut -1- and unscrew bolt -2-.
– Removing oil filter
Engine codes CAWA, CAWB, CBFA, CCTA, CCTB, BZB,
CGYA ⇒ page 225 .
Engine codes CCZA, CCZB, CCZC, CCZD, CDAA, CDAB
⇒ page 229 .
– Detach cable retainer -arrows-.
– Detach cables -arrows- from intake manifold.
478
Rep. gr.24 - Mixture preparation - injection
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4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
– Unscrew nuts -A- and remove bolts -arrows- for intake mani‐
fold using socket Torx T30 - T10347- .
– Carefully pull intake manifold with fuel rail slightly away from
cylinder head.
– Disconnect electrical connector -arrow- from intake manifold
flap potentiometer - G336- and remove intake manifold.
– Seal intake ports with a clean cloth.
Note
The injectors can remain in the fuel rail.
– Disconnect fuel rail from intake manifold ⇒ page 480 .
Installing:
•
Injectors must be installed in cylinder head. Installing injectors
⇒ page 481
– Fit intake manifold onto studs (left and right) on cylinder head.
Note
Observe correct installation position of injectors and on cable re‐
tainer (below intake manifold) when positioning intake manifold.
•
If, during intake manifold installation, the intake manifold has
to be pulled out again slightly and the injectors remain in the
fuel rail, Then pull the injectors out from the fuel rail again and
again insert the injectors into the cylinder head.
Further assembly is performed in the reverse order of removal.
During this procedure, observe the following:
– On engaging cable retainer onto intake manifold, also clip in
the other two retainers.
Specified torques: refer to assembly overview of intake manifold
⇒ page 469 .
Specified torques: refer to assembly overview of fuel rail
⇒ page 472 .
2. Injection system
479
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4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
2.9.1
Removing and installing fuel rail
Note
Intake manifold must be removed; removing intake manifold
⇒ page 473 .
– Pull activated charcoal filter system solenoid valve 1 - N80-
-arrow- from retainer.
– Loosen non-return valve -1- and fuel line -2-.
– Open hose clip -1-.
– Remove both bolts -arrows- from fuel rail.
– Pull off fuel rail from intake manifold.
Installing
– Push fuel rail -1- into supports -2- to stop.
– Push fuel rail in -direction of arrow- so that fuel rail engages in
retaining lugs -3- on top of intake manifold.
480
Rep. gr.24 - Mixture preparation - injection
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4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
– Tighten both bolts -arrows- from fuel rail.
– Install non-return valve and fuel line.
– Continue installation in reverse order of removal.
– Re-connect electrical connectors.
– Install intake manifold ⇒ page 473 .
Specified torques
Adapter for fuel line to fuel rail (renew)
Fuel line (union nut) to adapter for fuel rail
40 Nm
27 Nm
2.10
Removing and installing injectors
Special tools and workshop equipment required
♦ Tool set - T10133-
Note
Puller - T10133/2- has been modified and is now designated pull‐
er - T10133/2A- . If the new tool is not yet available in the
workshop, perform the modification yourself.
Convert puller - T10133/2- tool to puller - T10133/2A- tool.
Special tools and workshop equipment required
♦ Round file approx. 6 mm
– File out a semi-circular recess as shown in the illustration. The
recess allows the tool to be pushed further onto the injector so
the contact surface is increased.
– For identification purposes, mark the modified tool with the
letter “A” after the tool number.
2. Injection system
481
2024 VW Passat Owner's Manual
VW Passat B7 Service & Repair Manual
VW Passat B6 Service & Repair Manual
