P
r
o
t
e
c
t
e
d
b
y
c
o
p
y
r
i
g
h
t
.
C
o
p
y
i
n
g
f
o
r
p
r
i
v
a
t
e
o
r
c
o
m
m
e
r
c
i
a
l
p
u
r
p
o
s
e
s
,
i
n
p
a
r
t
o
r
i
n
w
h
o
l
e
,
i
s
n
o
t
p
e
r
m
i
t
t
e
d
u
n
l
e
s
s
a
u
t
h
o
r
i
s
e
d
b
y
V
o
l
k
s
w
a
g
e
n
A
G
.
V
o
l
k
s
w
a
g
e
n
A
G
d
o
e
s
n
o
t
g
u
a
r
a
n
t
e
e
o
r
a
c
c
e
p
t
a
n
y
l
i
a
b
i
l
i
t
y
w
i
t
h
r
e
s
p
e
c
t
t
o
t
h
e
c
o
r
r
e
c
t
n
e
s
s
o
f
i
n
f
o
r
m
a
t
i
o
n
i
n
t
h
i
s
d
o
c
u
m
e
n
t
.
C
o
p
y
r
i
g
h
t
b
y
V
o
l
k
s
w
a
g
e
n
A
G
.
23 – Mixture preparation - injection
1 Diesel direct injection system
Note
The diesel direct injection system control unit -J248- is equipped
with a fault memory. Read fault memory before and after per‐
forming repairs or adjustments ⇒ Vehicle diagnostic tester.
Safety precautions ⇒ page 242 .
Rules for cleanliness ⇒ page 243 .
Assembly overview - intake manifold with attachments
⇒ page 244 .
Removing and installing pre-wired wiring harness for unit injectors
and glow plugs ⇒ page 246
Assembly overview - unit injector ⇒ page 251
Removing and installing unit injector ⇒ page 251
Cleaning unit injectors (engine codes BMN, BKP and BMR)
⇒ page 255
Removing and installing O-rings for unit injector ⇒ page 257 .
Assembly overview - air filter ⇒ page 259 .
1.1 Safety precautions
WARNING
When doing any repair work, especially in the engine compart‐
ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant, refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ Ensure that there is sufficient clearance to all moving or
hot components.
Observe following if test and measuring instruments are required
during a road test:
♦ Test and measuring instruments must always be secured to
rear seat and operated by a second person from this location.
If test and measuring instruments are operated from front pas‐
senger 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 prevent injuries to persons and/or damage to the injection and
glow plug system, the following must be noted:
♦ The ignition must be switched off before connecting or dis‐
connecting injection or glow plug system wiring or tester ca‐
bles.
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011
242 Rep. gr.23 - Mixture preparation - injection
To Next Page
Loading...
Need help?
General
