Engine Controls - Remove/install/overhaul: Removal & Installation Volkswagen Passat B4

Removal & Installation

1. Distributor removal procedure not available at time of publication. To install distributor, ensure cylinder No. 1 is at TDC of compression stroke.
2. Align mark on camshaft sprocket with mark on rear toothed-belt guard. Turn rotor so that it points to cylinder No. 1 mark on distributor housing. Insert distributor into engine. Check ignition timing.

1. Obtain radio anti-theft code. Disconnect negative battery cable. Remove luggage compartment floor covering and fuel pump access cover. Disconnect wiring harness and fuel lines from fuel pump.
2. Using Wrench (3217), loosen fuel pump screw cap. Remove flange and sealing ring from fuel tank opening. Loosen fuel pump by twisting it to left. Remove fuel pump from fuel tank.
3. When installing fuel pump, ensure fuel gauge sending unit is not bent. Sending unit must be installed with a frontal angle of 70-75 degrees. Align mark on flange with fuel tank. To complete installation, reverse removal procedure.

Note. An in-tank (transfer) fuel pump is also used. Disconnect fuel lines and remove plastic retaining collar. Remove fuel pump from fuel tank. To install, reverse removal procedure.

1. Remove ignition wires. Remove hose from mass airflow sensor. Disconnect hose to fuel evaporative (frequency) solenoid valve at throttle body.
2. Disconnect throttle position sensor and idle air control valve. Disconnect accelerator cable from throttle body. Disconnect and plug coolant hoses at throttle body.
3. Disconnect hose from air intake heated tube. Detach fuel lines at cylinder head cover and remove from fuel rail. Disconnect vacuum hose from fuel pressure regulator. Remove upper intake manifold.
4. With upper intake manifold removed, disconnect wiring harness from fuel injector(s). Pry off retaining clip(s) from injector(s). Lubricate injector "O" rings with fuel, and install injectors. To complete installation, reverse removal procedure.