2.5l - Multiport Fuel Injection - Engine Code(s): Bpr & Bps (hatchback) Volkswagen New Beetle A4 рестайлинг

SAFETY PRECAUTIONS

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

Scheme 1

1. Do not touch or remove the ignition wires when the engine is running or turning at starter speed.
2. Only disconnect and reconnect wires for the injection and ignition system, including test leads, if the ignition is turned off.
3. Fuel pump is activated with switching on the ignition and by the door contact switch in the driver's door. Therefore for reasons of safety, the electrical connector -arrow- must be disconnected from the gw fuel delivery unit before opening the fuel supply system, if the battery is not disconnected.

If the engine is to be cranked at starting RPM without starting

Disconnect the electrical connectors from all the fuel injectors.

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

1. Test and measuring instruments must be secured to the rear seat and operated by a second person from this location.

If test and measuring instruments are operated from the front passenger 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 conclude work, erase the Diagnostic Trouble Code (DTC) memory of the Engine Control Module (ECM) since malfunctions were stored by removing the fuse. Refer to ENGINE CONTROL MODULE DTC MEMORY, CHECKING AND ERASING .

CLEAN WORKING CONDITIONS

When working on the fuel supply/injection system, pay careful attention to the following "5 rules" of cleanliness

1. Thoroughly clean all connections and the surrounding area before disconnecting.
2. Place parts that have been removed on a clean surface and cover them. Use lint free cloths.
3. Carefully cover or seal opened components, if repairs are not performed immediately.
4. Only install clean components: Only unpack replacement parts immediately prior to installation. Do not use parts that have been stored loose (for example, in tool boxes etc.).
5. When the system is open: Avoid working with compressed air if possible. Do not move vehicle unless absolutely necessary.

FUEL INJECTION SYSTEM

1. If the fuel supply system was opened, the system must be bled before starting the engine
2. Engine code BPS, refer to «FUEL SYSTEM, BLEEDING»(ref-492735-S11153269712012080600000) .
3. Engine code BPR, refer to «FUEL SYSTEM, BLEEDING»(ref-492735-S25733472772012080600000) .
4. Fuel hoses in the engine compartment may only be secured with spring type clamps, The use of clamp or screw type clips is not permissible.
5. Ignition must be switched off when disconnecting the battery. Obtain the radio code for radios with anti-theft coding before disconnecting the battery.
6. Observe the safety precautions after connecting battery. Refer to «Removal and Installation»(/volkswagen/new-beetle/a4-2005-2011/remont/charging-system/#battery-starter-generator-cruise-control-hatchback) .
7. For trouble free operation of the electrical components a voltage of at least 11.5 volts is necessary.
8. Do not use sealants containing silicone. Particles of silicone drawn into the engine, will not be burnt in the engine and damage the oxygen sensor.
9. If the engine only starts briefly and then shuts off again after troubleshooting, repairs or checking of components, it may be that the immobilizer is blocking the Engine Control Module (ECM). The ECM may have to be adapted. Refer to Vehicle diagnosis, testing and information system "Guided Functions".
10. It is possible that the control module will recognize a malfunction and store a Diagnostic Trouble Code (DTC) during some tests. After completing all tests and repairs, the DTC memory should therefore be checked and erased if necessary. Refer to «ENGINE CONTROL MODULE DTC MEMORY, CHECKING AND ERASING»(/volkswagen/new-beetle/a4-2005-2011/remont/fuel-system/#25l-multiport-fuel-injection-engine-codes-bpr-bps-hatchback__engine-control-module-dtc-memory-checking) .
11. Vehicles with an airbag are equipped with an emergency fuel shut off system. It reduces the risk of fire in an accident because the fuel pump relay switches the fuel pump off.
12. When opening the driver door, the fuel pump is activated for 2 seconds to build pressure in the fuel system. This improves comfort of engine start up behavior.

Safety precautions, refer to SAFETY PRECAUTIONS .

Rules of cleanliness, refer to CLEAN WORKING CONDITIONS .

Technical data, refer to TECHNICAL DATA .

COMPONENT LOCATION OVERVIEW

The following components are not displayed in the component location overview

Throttle Position (TP) sensor -G79- /accelerator pedal position sensor 2 -G185-.

1. Component location: In the accelerator pedal.

Leak Detection Pump (LDP) -V144

1. Component location: Refer to «EVAP SYSTEM ASSEMBLY OVERVIEW»(ref-492735-S33941596282012080600000) .

Clutch pedal switch -F36- /clutch pedal starter interlock switch -F194

1. Only for vehicles with a manual transmission.
2. Component location: On the clutch pedal.

Scheme 2

1. Camshaft Position (CMP) Sensor -G40
2. Knock Sensor (KS) 1 -G61- Component location, refer to «CYLINDER BLOCK COMPONENTS, REAR»(/volkswagen/new-beetle/a4-2005-2011/remont/mechanical/#25l-crankshaft-cylinder-block-engine-codes-bpr-bps-hatchback).
3. Knock Sensor (KS) 2 -G66- Component location, refer to «CYLINDER BLOCK COMPONENTS, REAR»(/volkswagen/new-beetle/a4-2005-2011/remont/mechanical/#25l-crankshaft-cylinder-block-engine-codes-bpr-bps-hatchback).
4. Secondary Air Injection (AIR) Solenoid Valve -N112- AIR system, refer to «SECONDARY AIR INJECTION ASSEMBLY OVERVIEW»(/volkswagen/new-beetle/a4-2005-2011/remont/auxiliary-emission-control-systems/#25l-exhaust-system-emission-controls-engine-codes-bpr-bps-hatchback). Checking, refer to «SECONDARY AIR INJECTION SOLENOID VALVE, CHECKING»(/volkswagen/new-beetle/a4-2005-2011/remont/auxiliary-emission-control-systems/#25l-exhaust-system-emission-controls-engine-codes-bpr-bps-hatchback__secondary-air-injection-solenoid-valve-checking).
5. Motronic Engine Control Module (ECM) -J220- Component location: In the plenum chamber. Replacing, refer to «ENGINE CONTROL MODULE»(/volkswagen/new-beetle/a4-2005-2011/remont/fuel-system/#25l-multiport-fuel-injection-engine-codes-bpr-bps-hatchback__engine-control-module).
6. Engine Coolant Temperature (ECT) Sensor -G62- If necessary release the pressure in the cooling system before removing.
7. Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 -N80- EVAP system, refer to «EVAP SYSTEM ASSEMBLY OVERVIEW»(ref-492735-S33941596282012080600000). Installed position: Arrow points in direction of flow.
8. Ignition Coil with Power Output Stage -N70, N127, N291, N292, N323- Removal and installation, refer to «IGNITION COILS WITH POWER OUTPUT STAGES»(/volkswagen/new-beetle/a4-2005-2011/remont/ignition-system/#25l-ignitionglow-plug-system-engine-codes-bpr-bps-hatchback__ignition-coils-with-power-output-stages).
9. Mass Air Flow (MAF) Sensor -G70- /Intake Air Temperature (IAT) Sensor -G42
10. Auxiliary Relay Carrier above Central Electronics Component location of: AIR pump relay -J299- see scheme 6 Power supply relay (terminal 30, B+) -J317- (Scheme 4)
11. Secondary Air Injection (AIR) Pump Motor -V101- Removal and installation, refer to «SECONDARY AIR INJECTION PUMP MOTOR»(/volkswagen/new-beetle/a4-2005-2011/remont/auxiliary-emission-control-systems/#25l-exhaust-system-emission-controls-engine-codes-bpr-bps-hatchback__secondary-air-injection-pump-motor).
12. Engine Speed (RPM) Sensor -G28- Component location, refer to «SEALING FLANGE AND DRIVE PLATE/FLYWHEEL ASSEMBLY OVERVIEW»(/volkswagen/new-beetle/a4-2005-2011/remont/mechanical/#25l-crankshaft-cylinder-block-engine-codes-bpr-bps-hatchback).
13. Throttle Valve Control Module -J338- Removal and installation, refer to «THROTTLE VALVE CONTROL MODULE»(/volkswagen/new-beetle/a4-2005-2011/remont/fuel-system/#25l-multiport-fuel-injection-engine-codes-bpr-bps-hatchback__throttle-valve-control-module).
14. Camshaft Adjustment Valve 1 -N205- Removal and installation, refer to «CYLINDER HEAD ASSEMBLY OVERVIEW»(/volkswagen/new-beetle/a4-2005-2011/remont/mechanical/#25l-cylinder-head-valvetrain-engine-codes-bpr-bps-hatchback).
15. Fuel Injector -N30, N31, N32, N33, N83- Removal and installation, refer to «FUEL INJECTORS»(/volkswagen/new-beetle/a4-2005-2011/remont/fuel-system/#25l-multiport-fuel-injection-engine-codes-bpr-bps-hatchback__fuel-injectors).
16. 6 Pin Harness Connector Component location: (Scheme 3) Contacts are gold plated. Black For the HO2S in front of the catalytic converter and O2S heater -Z19-.
17. Heated Oxygen Sensor (HO2S) in Front of the Catalytic Converter -G39-, 55 Nm Component location: In the exhaust manifold. Only use hot bolt paste G 052 118 A3 to grease the threads; do not let the hot bolt paste G 052 118 A3 get onto the slits of the oxygen sensor body
18. 4 Pin Harness Connector Only for engine code BPR. Component location: (Scheme 3) Contacts are gold plated. Black For the O2S in Center TWC, Bank 1 and O2S Heater - Center TWC.
19. Oxygen Sensor (O2S) in Center Three Way Catalytic Converter (TWC), Bank 1 -G465-, 55 Nm Only for engine code BPR. Component location: In center catalytic converter. Only use hot bolt paste G 052 118 A3 to grease the threads; do not let hot bolt paste G 052 118 A3 get onto the slits of the oxygen sensor body.
20. 4 Pin Harness Connector Component location: (Scheme 3) Contacts are gold plated. Brown For the O2S behind TWC and O2S heater 1 (behind TWC).
21. Oxygen Sensor (02S) behind Three Way Catalytic Converter (TWC) -G130-, 55 Nm Component location: In rear catalytic converter. Only use hot bolt paste G 052 118 A3 to grease the threads; do not let hot bolt paste G 052 118 A3 get onto the slits of the oxygen sensor body

Scheme 3

1. On the vehicle underside

1. Connector for O2S behind TWC
2. Connector for HO2S
3. Connector for O2S in Center TWC, Bank 1

Scheme 4

1. In 13 pin auxiliary relay carrier -13-.

Scheme 5

1. In the central electronics -4

1. In 10 pin auxiliary relay carrier -13

1. In 3 pin auxiliary relay carrier -13

Scheme 6

1. Hose for Crankcase Ventilation From the cylinder head cover.
2. Ventilation Hose
3. Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 -N80
4. Line Vehicles through Model Year (MY) 2009 only. On vehicles from MY 2010, the vacuum connection on the intake manifold is sealed with a cap (new vacuum connection on the vacuum pump/brake booster vacuum line).
5. Vacuum Hose Vehicles through MY 2009 only. From the Leak Detection Pump (LDP) -V144-.
6. Bolt, 9 Nm
7. Bracket For line
8. Fuel Rail Assembly overview, refer to «FUEL RAIL AND INJECTORS ASSEMBLY OVERVIEW»(/volkswagen/new-beetle/a4-2005-2011/remont/fuel-system/#25l-multiport-fuel-injection-engine-codes-bpr-bps-hatchback) .
9. Fuel Supply Line
10. Gasket Replace Note the installed position: Casting mark points upward.
11. Intake Manifold Removal and installation, refer to «INTAKE MANIFOLD»(/volkswagen/new-beetle/a4-2005-2011/remont/fuel-system/#25l-multiport-fuel-injection-engine-codes-bpr-bps-hatchback__intake-manifold) .
12. O-ring Replace if damaged.
13. Manifold Absolute Pressure (MAP) Sensor -G71
14. Bolt, 3.5 Nm
15. Coolant Connections Only for the throttle valve control module heated by coolant.
16. Bolt, 6.5 Nm
17. Throttle Valve Control Module -J338- With the throttle drive (for Electronic Power Control (EPC)) -G186-, throttle drive angle sensor 1 (for EPC)) -G187- and throttle drive angle sensor 2 (for EPC) -G188- When replacing, erase the adaptation values and adapt the Engine Control Module (ECM) to the throttle valve control module. Refer to vehicle diagnosis, testing and information system "Guided Functions".
18. Seal Replace if damaged

Scheme 7

1. Bolt, 3.5 Nm
2. Fuel Rail
3. Fuel Supply Line
4. O-ring Replace Lubricate with clean engine oil.
5. Retaining Clip Make sure the clip is correctly seated on the fuel injector and rail.
6. Fuel Injector -N30, N31, N32, N33, N83- Removal and installation, refer to «FUEL INJECTORS»(/volkswagen/new-beetle/a4-2005-2011/remont/fuel-system/#25l-multiport-fuel-injection-engine-codes-bpr-bps-hatchback__fuel-injectors) . Checking, refer to «FUEL INJECTORS, CHECKING INJECTION QUANTITY AND FOR LEAKS»(/volkswagen/new-beetle/a4-2005-2011/remont/fuel-system/#25l-multiport-fuel-injection-engine-codes-bpr-bps-hatchback__fuel-injectors-checking-injection-quantity-and) .
7. Intake Manifold
8. Protective Cap
9. Breather Valve

Scheme 8

1. Intake Tube To the throttle valve control module.
2. Spring Type Clip
3. Mass Air Flow (MAF) Sensor -G70- with Intake Air Temperature (IAT) Sensor -G42
4. O-ring Replace
5. Bolt, 2 Nm
6. Upper Air Filter Housing
7. Bolt, 2 Nm
8. Filter Element
9. Air Duct Secured in the wheel housing.
10. Bolt, 8 Nm
11. Air Duct Secured to the battery holder.
12. Lower Air Filter Housing
13. Intake Tube For warm air.

TECHNICAL DATA

FASTENER TIGHTENING SPECIFICATIONS

FUEL INJECTORS, CHECKING INJECTION QUANTITY AND FOR LEAKS

Note. Observe safety precautions. Refer to SAFETY PRECAUTIONS . Observe the rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .

Special tools and workshop equipment required

1. Remote control VAG 1348/3A
2. Adapter cable VAG 1348/3-2
3. Injection rate tester VAG 1602
4. Connector test set VAG 1594C

Checking for Leaks

1. Fuel pressure must be OK, checking. Refer to «FUEL PRESSURE REGULATOR AND RESIDUAL PRESSURE CHECKING, ENGINE CODE BPS»(/volkswagen/new-beetle/a4-2005-2011/remont/fuel-system/#25l-multiport-fuel-injection-engine-codes-bpr-bps-hatchback__fuel-pressure-regulator-and-residual-pressure) .

Remove the fuel rail -2- with injectors installed. Refer to FUEL INJECTORS , and place it on a clean cloth.

Scheme 9

Do not disconnect the battery and do not disconnect the fuel supply line at the quick acting coupling or at the fuel rail.

1. Harness connectors must be disconnected from the fuel injectors.

Fold the rear seat bench forward.

Remove the cover from fuel delivery unit.

Disconnect the 4 pin connector from the fuel delivery unit.

Using an adapter cable, connect terminal -1- of the fuel pump to the battery positive (+).

Scheme 10

Connect terminals -4- of the connector and fuel pump using an adapter cable from VAG 1594C.

Note. This step allows the fuel pump to run when the engine is not running.

Check the injectors for leaks (visual inspection).

1. Only 1 to 2 drops per minute may emit from each injector when the fuel pump is running.

If the fuel loss is greater

Disconnect the connection to the battery positive (+) and replace the leaking fuel injector. Refer to FUEL INJECTORS .

Note. If the fuel injectors are replaced, erase the adaptation values and adapt the Engine Control Module (ECM) again. Refer to vehicle diagnosis, testing and information system "Guided Functions". Always use new seals.

Injection Quantity, Checking

1. Fuel pressure must be OK, checking. Refer to «FUEL PRESSURE REGULATOR AND RESIDUAL PRESSURE CHECKING, ENGINE CODE BPS»(/volkswagen/new-beetle/a4-2005-2011/remont/fuel-system/#25l-multiport-fuel-injection-engine-codes-bpr-bps-hatchback__fuel-pressure-regulator-and-residual-pressure) .
2. Fuel rail is removed.
3. Fuel injectors installed in the fuel rail and fuel line connected.
4. Fuel pump runs (connected to battery with adapter cables)

Place a fuel injector to be tested into a graduated measuring glass from VAG 1602.

Using the adapter cables from VAG 1594C, connect one terminal of the injector to be checked to engine ground (GND).

Scheme 11

Connect the second terminal of the injector with the adapter cable to the VAG 1348/3A using VAG 1348/3-2.

Connect the alligator clip to the battery positive (+).

Operate the VAG 1348/3A for 30 seconds.

Repeat the check on the other injectors. Use new graduated measuring glasses for this.

After all fuel injectors have been activated, place the graduated measuring glasses on a level surface and compare the quantity of fuel.

1. Specified value: 85 to 105 ml per injector

While checking the injection quantity, the spray pattern should also be checked. Spray pattern must be the same for all injectors.

If the measured value of one or more injectors is below or above the indicated specified value

Replace the faulty injector. Refer to FUEL INJECTORS .

FUEL PRESSURE REGULATOR AND RESIDUAL PRESSURE CHECKING, ENGINE CODE BPS

Note. Observe safety precautions. Refer to SAFETY PRECAUTIONS . Observe the rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .

Special tools and workshop equipment required

1. Fuel inj. pressure gauge-cis VAG 1318
2. Valve adapter VAG 1318/9
3. Adapter VAG 1318/17
4. Fuel line feed adapter VAG 1318/23
5. Remote control VAG 1348/3A

Note. The fuel pressure regulator regulates the fuel pressure to approximately 4 bar. The fuel pressure regulator is located on the fuel filter. From May 2006, the fuel pressure regulator is integrated in the fuel filter and cannot be replaced. Observe the safety precautions. Refer to SAFETY PRECAUTIONS . Observe the rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .

Disconnect the 4 pin harness connector -arrow- from the fuel delivery unit.

Disconnect the fuel supply line -1- from the filter and catch any leaking fuel with a cloth.

Scheme 12

Note. Press in the securing ring to disengage the fuel line.

Connect the VAG 1318 with VAG 1318/9 and VAG 1318/17 to the fuel filter -1- and to the supply line -2-.

Scheme 13

Open the shut off lever on the VAG 1318. The lever points in the direction of flow.

Bleed the fuel supply system. Refer to FUEL SYSTEM, BLEEDING .

Reconnect the 4 pin harness connector to the fuel delivery unit.

Start the engine and run at idle speed.

Measure the fuel pressure.

1. Specified value: approximately 4.0 bar

If the specification is not obtained

Switch off ignition.

Check the delivery quantity of the fuel pump. Refer to DELIVERY QUANTITY, CHECKING .

If the fuel pump is OK, replace the fuel pressure regulator FUEL FILTER ASSEMBLY OVERVIEW => Fuel Pressure Regulator .

Note. From May 2006, the fuel pressure regulator is integrated in the fuel filter and cannot be replaced.

If specified value is achieved

Switch off ignition.

Now check for leaks and residual pressure (entire system). Observe pressure drop on the VAG 1318.

1. After 10 minutes there must be a residual pressure of at least 3.0 bar.

If the holding pressure drops below 3 bar

Start the engine and run at idle speed.

Wait until the pressure has built up, then switch off the ignition. Shut off lever on the VAG 1318 must be closed at the same time (lever perpendicular to direction of flow -arrow-).

Scheme 14

Observe the pressure drop (engine side) on the VAG 1318.

If the pressure drops again

Check line connections, O-rings at fuel rail and injectors for leaks. Refer to FUEL INJECTORS, CHECKING INJECTION QUANTITY AND FOR LEAKS .

Check the VAG 1318 for leaks.

Note. Before removing the VAG 1318, place clean cloths around the line connection which is to be disconnected.

If the pressure does not drop

Check line connections to the fuel tank and check valve in the fuel pump. Refer to FUEL PUMP CHECK VALVE, CHECKING .

If the check valve is OK, replace the fuel pressure regulator in FUEL FILTER ASSEMBLY OVERVIEW .

Note. From May 2006, the fuel pressure regulator is integrated in the fuel filter and cannot be replaced.

Bleed the fuel supply system. Refer to FUEL SYSTEM, BLEEDING .

FUEL PRESSURE REGULATOR AND RESIDUAL PRESSURE CHECKING, ENGINE CODE BPR

Note. Observe the safety precautions. Refer to SAFETY PRECAUTIONS . Observe the rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .

Special tools and workshop equipment required

1. Fuel inj. pressure gauge-cis VAG 1318
2. Valve adapter VAG 1318/9
3. Adapter VAG 1318/17
4. Fuel line feed adapter VAG 1318/23
5. Remote control VAG 1348/3A

Note. The fuel pressure regulator regulates the fuel pressure to approximately 4 bar. The fuel pressure regulator is located on fuel filter (in the fuel tank).

RESIDUAL PRESSURE, CHECKING

Fold the rear seat bench forward.

Remove the cover from fuel delivery unit.

Disconnect the 4 pin connector -1-.

Scheme 15

Disconnect the fuel supply line -3- and catch the leaking fuel with a cleaning cloth.

Scheme 16

Note. Press the securing ring to disengage the line.

Connect the VAG 1318 as described to the VAG 1318/9 and VAG 1318/17 (figure shows 2.0 L engine).

Scheme 17

Open the shut off lever on the VAG 1318. Lever points in direction of flow -A-.

Bleed the fuel supply system. Refer to FUEL SYSTEM, BLEEDING .

Reconnect the 4 pin harness connector to the fuel delivery unit.

Start the engine and let run at idle.

Measure the fuel pressure.

1. Specified value: approximately 4.0 bar

If the specification is not obtained

Switch off the ignition.

Check whether the fuel pump builds up this pressure and can maintain. Refer to FUEL PUMP CHECK VALVE, CHECKING .

Check the fuel pressure regulator. Refer to FUEL PRESSURE REGULATOR, CHECKING .

If specified value is achieved

Switch off the ignition.

Now check for leaks and residual pressure (entire system). Observe pressure drop on the VAG 1318. After 10 minutes, at least 3.0 bar positive pressure must remain.

If the residual pressure drops below 3 bar

Start the engine and let run at idle.

Wait until pressure has built up, then switch off the ignition. Shut off lever on the VAG 1318 must be closed at the same time (lever perpendicular to direction of flow -arrow-).

Observe pressure drop (engine side) on the VAG 1318.

If pressure drops again

Check line connections to the fuel rail and injectors for leaks.

Check the VAG 1318 for leaks.

Note. Before removing the VAG 1318, place clean cloths around line connection which is to be disconnected.

If the pressure does not drop

Check the fuel pump check valve. Refer to FUEL PUMP CHECK VALVE, CHECKING .

Check the fuel pressure regulator. Refer to FUEL PRESSURE REGULATOR, CHECKING .

FUEL PRESSURE REGULATOR, CHECKING

1. Fuel pump check valve OK, checking. Refer to «FUEL PUMP CHECK VALVE, CHECKING»(ref-492735-S20502571062012080600000) .
2. Fuel supply line OK.

Disconnect the fuel supply line -3- and catch the leaking fuel with a clean cloth.

Note. Press the securing ring to disengage the line.

Connect the VAG 1318 with VAG 1318/23 and VAG 1318/17 to the fuel supply line.

Scheme 18

Close the VAG 1318 shut off lever (lever stands perpendicular to direction of flow - position -B-).

Switch the ignition on and off until the fuel pressure on the VAG 1318 is 4 bar.

Observe the pressure drop on the VAG 1318.

1. After 30 minutes the pressure must not drop below a 3 bar decrease.

If the pressure drops further

Check line connections for leaks.

If no malfunctions are found in connections

Replace the fuel pressure regulator.

ENGINE CONTROL MODULE DTC MEMORY, CHECKING AND ERASING

Special tools and workshop equipment required

1. Vehicle diagnostic tester

Connect the vehicle diagnosis, testing and information system to the vehicle.

Start the engine and run at idle speed.

Only if engine does not start

Switch on the ignition.

Selecting operating mode

Press button on display for "Vehicle On Board Diagnostic (OBD)".

Selecting vehicle system

Press button "01 - Engine electronics" on display.

The control module identification with coding -2- as well as Vehicle Identification Number (VIN) in the center area and identification of anti-theft immobilizer appear on the display.

Scheme 19

Note. The VAS 5051B can create a printout. Press the "print" button if required.

Selecting diagnosis function

Press button "02 - Check DTC memory" on display.

If no malfunction is stored in the Engine Control Module (ECM), "0 DTC(s) detected" is displayed.

If malfunctions are stored in the ECM, these are shown one below another on the display.

Press the <-- key.

Press button "05 - Erase DTC memory" on display.

Press function "06 - End output".

Note. If the Diagnostic Trouble Code (DTC) memory was erased, the readiness code must be generated again. Refer to vehicle diagnosis, testing and information system "Guided Fault Finding".

THROTTLE VALVE CONTROL MODULE

Special tools and workshop equipment required

1. Hose clamps up to 25 mm dia. 3094
2. Torque wrench VAG 1410
3. Spring type clip pliers VAS 5024A or hose clip pliers VAS 6340

Removing

Note. Observe the rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .

Remove the engine cover.

Remove the intake hose -4- between the throttle valve control module -J338- and the Mass Air Flow (MAF) sensor -G70-. To do so, disconnect air hoses -1 and 2- (compress securing ring) and remove spring clamp -3-.

Scheme 20

Disconnect the connector -1- and bleeder hose -2-.

Scheme 21

Remove the bolts -arrows-.

Note. Seal the intake passage in the intake manifold using a clean cloth.

Clamp off the coolant hoses using 3094 and disconnect them from the throttle valve connections -arrows-.

Scheme 22

Note. Coolant hoses are only for a throttle valve control module heated by coolant

Installing

Installation is performed in the reverse order of removal. When doing this note the following

1. Replace the seal for throttle valve control module if damaged.
2. Coolant hose connections are only for coolant heated throttle valve control modules.
3. Make sure the air hoses -1 and 2- are installed securely.
4. When replacing, erase the adaptation values and adapt the Engine Control Module (ECM) to the throttle valve control module. Refer to vehicle diagnosis, testing and information system "Guided Functions".

Tightening Specifications

INTAKE MANIFOLD

Special tools and workshop equipment required

1. Torque wrench (5-50 Nm) VAG 1331
2. Socket and extended bit T10107A

Removing

Note. Observe the safety precautions. Refer to SAFETY PRECAUTIONS . Observe the rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .

First, check whether a coded radio is installed. If necessary, obtain the anti-theft code.

With the ignition switched off, disconnect the battery ground (GND) cable. Refer to Removal and Installation .

Remove the engine cover.

Vehicles through Model Year (MY) 2009

Remove the vacuum line -1-, ventilation line -2- and fuel supply line -3- and catch any leaking fuel with a clean cloth.

Vehicles from MY 2010

Remove the ventilation line -2- and fuel supply line -3-. Catch any leaking fuel with a clean cloth.

Continuation for All Vehicles

Note. Press the securing ring to disengage the lines.

Disconnect all connectors -1- from the fuel injectors as well as connectors -2 and 6-.

Scheme 23

Remove the wiring harness -3- from the transport strap.

Pull all clamps -4- and retaining ring -5- from the locking mechanism.

Remove bolts -7- and remove the transport strap.

Remove the throttle valve control module -J338-. Refer to THROTTLE VALVE CONTROL MODULE . The coolant hoses remain connected, if equipped.

Note. Coolant hoses are only for a throttle valve control module heated by coolant

Disconnect the connector -1- and hose for the crankcase ventilation -3-.

Scheme 24

Remove the wiring harness -2-. To do so, carefully press off clips -arrows-.

Bring the lock carrier into service position. Refer to Description and Operation .

Support lock carrier using a sleeve -B-, 80 millimeters (mm) in length, for example, from VW 540/1 A and a M8 x 100 bolt -A-.

Scheme 25

Remove nut -1- for the line -2- for the power steering at the engine and disconnect the line from the threaded pin.

Scheme 26

Remove the oil dipstick out of the intake manifold and press retaining ring -4- downward.

Remove the oil dipstick guide tube from the bottom of the cylinder block.

Cover the opening in the cylinder block.

Loosen the intake manifold bolts -arrows- using T10107A.

Scheme 27

Bolts remain in the intake manifold.

Remove the intake manifold upward at an angle.

Make sure that no bolts fall out.

Seal the intake passages in the cylinder head using clean cloths.

Reinsert the guide tube for oil dipstick into the cylinder block and secure it.

If the manifold must be replaced

Remove the fuel rail with injectors. Refer to FUEL INJECTORS .

Disconnect the vacuum hose for the Leak Detection Pump (LDP) -V144-.

Remove the Manifold Absolute Pressure (MAP) sensor -G71-.

Installing

Installation is performed in the reverse order of removal. When doing this note the following

1. Replace the seals between the intake manifold and cylinder head.
2. Tighten the bolts for the intake manifold starting inside working toward the outside and in a diagonal sequence.
3. Replace the oil dipstick guide tube O-ring.

Bleed the fuel supply system. Refer to one of the following

1. Engine code BPS, refer to «FUEL SYSTEM, BLEEDING»(ref-492735-S11153269712012080600000) .
2. Engine code BPR, refer to «FUEL SYSTEM, BLEEDING»(ref-492735-S25733472772012080600000) .

Connect the battery. Refer to Removal and Installation .

Tightening Specifications

FUEL INJECTORS

Removing

Note. Observe the safety precautions. Refer to SAFETY PRECAUTIONS . Observe the rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .

First, check whether a coded radio is installed. If necessary, obtain the anti-theft code.

With ignition switched off, disconnect the battery ground (GND) cable. Refer to Removal and Installation .

Remove the engine cover.

Disconnect the ventilation line -2- and fuel supply line -3-. Catch any draining fuel with a clean cloth.

Note. Press the securing ring to disengage the lines.

Disconnect all connectors -1- from the fuel injectors as well as connectors -2 and 6-.

Remove the wiring harness -3- from the transport strap.

Pull all clamps -4- and retaining ring -5- from the locking mechanism.

Remove bolts -7- and remove the transport strap.

Remove bolts -1- and pull the fuel rail with injectors evenly out of the intake manifold.

Seal or cover the openings in the intake manifold.

Pull off the retaining clips -3- and then the injectors.

Installing

Install new O-rings for the injectors and lubricate them lightly with clean engine oil.

Press the injectors into the fuel rail so that the tabs -1 and 2- align.

Scheme 28

Slide the retaining clip -3- as shown into the groove of the injector. Collar -4- must be located correctly in the cutout of the retaining clip on both sides.

After assembling, check all injectors for correct installation.

Install the fuel rail with secured injectors to the intake manifold and press it in uniformly.

Secure the fuel rail to the intake manifold.

The rest of the installation follows the reverse of the removal procedures. When doing this note the following

Bleed the fuel supply system. Refer to one of the following

1. Engine code BPS, refer to «FUEL SYSTEM, BLEEDING»(ref-492735-S11153269712012080600000) .
2. Engine code BPR, refer to «FUEL SYSTEM, BLEEDING»(ref-492735-S25733472772012080600000) .

Connect the battery. Refer to Removal and Installation

Tightening Specifications

ENGINE CONTROL MODULE

Note. If the Engine Control Module (ECM) will be replaced, connect the vehicle diagnostic tester and perform the "Replacing Engine Control Module" guided function.

Removing

Switch off the ignition.

Remove the inner cover of the left plenum chamber. Refer to Removal and Installation .

Carefully press off the mounting bracket -arrow-.

Scheme 29

Disengage the connectors from the control module and then disconnect the connectors.

Remove the control module.

Installing

Connect and engage the harness connectors at the control module.

Insert the new control module in the retaining frame.

SPECIAL TOOLS

Special tools and workshop equipment required

Scheme 30

Scheme 31

1. Torque wrench (5-50 Nm) VAG 1331
2. Socket and extended bit T10107A

Scheme 32

Special tools and workshop equipment required

1. Remote control VAG 1348/3A
2. Adapter cable VAG 1348/3-2
3. Injection rate tester VAG 1602
4. Connector test set VAG 1594C

Scheme 33

Special tools and workshop equipment required

1. Fuel inj. pressure gauge-cis VAG 1318
2. Valve adapter VAG 1318/9
3. Adapter VAG 1318/17
4. Fuel line feed adapter VAG 1318/23
5. Remote control VAG 1348/3A

Scheme 34

Special tools and workshop equipment required

1. Hose clamps up to 25 mm dia. 3094
2. Torque wrench VAG 1410
3. Spring type clip pliers VAS 5024A or hose clip pliers VAS 6340

See also:
• Removal and Installation
• CYLINDER BLOCK COMPONENTS, REAR
• SECONDARY AIR INJECTION ASSEMBLY OVERVIEW
• SECONDARY AIR INJECTION SOLENOID VALVE, CHECKING
• IGNITION COILS WITH POWER OUTPUT STAGES
• SECONDARY AIR INJECTION PUMP MOTOR
• CYLINDER HEAD ASSEMBLY OVERVIEW
• Description and Operation
• Removal and Installation
• ENGINE CONTROL MODULE DTC MEMORY, CHECKING AND ERASING
• SAFETY PRECAUTIONS
• CLEAN WORKING CONDITIONS
• TECHNICAL DATA
• ENGINE CONTROL MODULE
• THROTTLE VALVE CONTROL MODULE
• FUEL INJECTORS
• FUEL RAIL AND INJECTORS ASSEMBLY OVERVIEW
• INTAKE MANIFOLD
• FUEL INJECTORS, CHECKING INJECTION QUANTITY AND FOR LEAKS
• FUEL PRESSURE REGULATOR AND RESIDUAL PRESSURE CHECKING, ENGINE CODE BPS
• FUEL PRESSURE REGULATOR, CHECKING