Volkswagen Workshop Service and Repair Manuals

Removing and installing cylinder head cover → Chapter „Safety precautions“ → Chapter „Rules for cleanliness“ → Chapter „Instructions for working on fuel system“ → Chapter „Schematic overview (Polo)“ → Chapter „Removing and installing injector seal in cylinder head cover“ Special tools and workshop equipment required

t  Torque wrench -V.A.G 1331-

t  Lambda probe open ring spanner set -3337-

t  Pliers -3314- »Carry out the following work sequence« Removing –  Remove engine cover panel → Chapter. –  Remove noise insulation at injectors. –  Remove injectors → Chapter.

–  Position pliers -3314- with groove -arrow A- on support sleeve shoulder -arrow B-.

–  Carefully pull connector off glow plug in direction of -arrow-.

–  Pull connector of position sender for charge pressure positioner -G581--arrow- off turbocharger and guide wiring out of retainers. (Polo)

–  Unclip coolant return hose -arrows- and place coolant line to one side. The installation position of the coolant return hose can vary. (Golf, Golf Plus, Passat, Touran)

–  Unscrew the securing bolt -arrows- and place the coolant return line to the side.

–  Golf: Pull connector -2- off pressure differential sender -G 505-. Continuation for all vehicles:

–  Unscrew the securing bolts on the intake manifold -arrows- and move the coolant return line to the side.

–  Unscrew bolts -3- + -4-, remove lifting eye.

–  Remove high-pressure line between high-pressure pump -1- and high-pressure accumulator -3-.

–  Open clamp -arrow- and pull line off high-pressure accumulator.

–  Remove bolts -arrows-.

–  Pull connector off fuel pressure regulating valve -N 276--arrow-. –  Remove wiring harness from high-pressure accumulator and place wiring harness to one side.

–  Remove the connector on the fuel pressure sender -G 247--2-.

–  Remove high-pressure accumulator.   Caution Make sure that no wiring connections are damaged when disconnecting the connectors. Otherwise the whole wiring harness will need to be renewed. Do not compress the pliers -3314- too firmly to separate the connectors, otherwise the support sleeve may be damaged.

–  Pull vacuum line off cylinder head cover -arrow A-. –  Remove remaining vacuum hoses from bracket on cylinder head cover. –  Remove remaining electric cables/wires. –  Remove upper toothed belt guard. –  Remove breather line between cylinder head cover and intake hose. Press quick-release fasteners to do this. –  Remove securing bolts from cylinder head cover. –  Remove cylinder head cover.

–  Unclip the cylinder head cover at the locking lugs -arrows - on the rear toothed belt guard. Installation is performed in the reverse sequence. In the process, note the following: → Chapter „Safety precautions“ → Chapter „Rules for cleanliness“ Observe instructions for working on fuel system → Chapter   Note Renew seal for bolts if damaged. –  Screw on cylinder head cover hand-tight in the sequence -1…6-.

–  Tighten bolts to 10 Nm in the sequence -1…6-. –  Ensure that cylinder head cover is correctly clipped to toothed belt guard.   Note For illustration purposes, the camshaft pulley is shown removed.

–  To do this, press toothed belt guard (using a screwdriver if necessary) against cylinder head cover in area of clips -arrows- until clips audibly engage in each other. –  Check clearance between hub and toothed belt guard. After any work on the fuel system Connect a → Vehicle diagnostic tester. Perform the function „Fuel pump activation (Filling/bleeding fuel system)“ in „Guided functions“ → Chapter.