Volkswagen Workshop Service and Repair Manuals

• Plug
• ◆ Note installation position
• 3 Nm
• ◆ Notes on installing
• Air cleaner
• ◆ Dismantling and assembling => Page 24-25
• ◆ Removing and installing air cleaner
  => Page 24-28 , Fig. 3
• Cable/line guide
• ◆ Clipped onto fuel rail
• 10 Nm

• Fuel manifold with injectors
• ◆ Dismantling and assembling => Page 24-22
• Intake manifold
• ◆ Dismantling and assembling => Page 24-19
• From activated charcoal filter solenoid valve (N80)*/**

=> Repair group 20; Activated charcoal filter system

• Connector
• ◆ Black, 6-pin
• ◆ For throttle valve control part (J338)
• ◆ Connector contacts are gold-plated
• From brake servo

• Gasket
• ◆ Renew
• From exhaust gas recirculation valve

=> Repair group 26; Exhaust gas recirculation system; Servicing parts of the exhaust gas recirculation system

• 5 Nm
• Engine speed sender (G28)*
• ◆ To remove, remove starter:

=> Electrical system; Repair group 27; Starter; Removing and installing starter

• ◆ Checking => Page 24-68
• ◆ Fitting location => Page 24-1 , fitting location overview

• Lambda probe 2 after catalyst (G130)*, 50 Nm
• ◆ Grease only the threads with "G 052 112 A3"; "G 052 112 A3" must not get into the slots on the probe body
• ◆ Remove and install with ring spanner 3337
• ◆ With 4-pole connector
• ◆ Contacts 3 and 4 gold plated
• ◆ Probe heating voltage supply via fuel pump relay (J17)
• ◆ Checking Lambda probe and Lambda regulation after catalyst => Page 24-100
• ◆ Checking Lambda probe heating for Lambda probe after catalyst => Page 24-38
• ◆ Location: Behind catalyst

• Lambda probe 1 before catalyst (G39)*, 50Nm
• ◆ Grease only the threads with "G 052 112 A3"; "G 052 112 A3" must not get into the slots on the probe body
• ◆ Remove and install with ring spanner 3337
• ◆ With 6-pin connector
• ◆ Contacts gold plated
• ◆ Probe heating voltage supply via fuel pump relay (J17)
• ◆ Checking Lambda probe and Lambda regulation before catalyst
  => Page 24-93
• ◆ Checking Lambda probe heating before catalyst => Page 24-33
• ◆ Checking Lambda probe ageing Lambda probe 1 => Page 24-106
• ◆ Fitting location: In exhaust manifold

• Thermostat housing
• Retaining clip
• ◆ Check seated securely
• Coolant temperature sender (G62)*
• ◆ For engine control unit
• ◆ With coolant temperature gauge sender (G2)
• ◆ If necessary release pressure in cooling system before removing
• ◆ Resistance value between contacts C and D
  , Fig. 1
• ◆ Checking
• Connector
• ◆ Black, 4-pin
• ◆ For coolant temperature sender (G62) and coolant temperature gauge sender (G2)
• ◆ Contacts gold plated

• Plug
• ◆ If necessary release pressure in cooling system before removing
• O-ring
• ◆ Renew if damaged
• Retaining frame
• Connector
• ◆ Only disconnect or connect with ignition switched off
• Engine control unit*
• (4LV injection system control unit -J537)
• ◆ Checking voltage supply => Page 24-112
• ◆ Procedure after voltage supply open circuit => Page 24-115
• ◆ Renew => Page 24-117
• ◆ Coding => Page 24-120
• ◆ Fitting location => Page 24-1 , engine compartment overview

• Warm air intake hose
• ◆ From warm air collector plate:

=> Repair group 26; Removing and installing parts of exhaust system

• Connecting piece for cold air intake
• ◆ Additionally secured on body with retaining clip
• Seal
• ◆ Renew
• 20 Nm
• Vacuum hose

• Supply hose
• ◆ Black with white marks
• ◆ Secure with spring-type clips
• ◆ Check securely seated
• ◆ From fuel filter:

=> Repair Group 20; Removing and installing parts of fuel supply system; Removing and installing fuel tank with attachments and fuel filter

• Return hose
• ◆ Blue or with blue marking
• ◆ Secure with spring-type clips
• ◆ Check securely seated
• ◆ To the fuel delivery unit in fuel tank

=> Repair Group 20; Removing and installing parts of fuel supply system; Removing and installing fuel tank with attachments and fuel filter

• Connector
• ◆ Black, 2-pin
• ◆ For injector (N30...N33)
• Connector
• ◆ Black, 2-pin
• ◆ For knock sensor 1 (G61)
• ◆ Connector contacts are gold-plated
• ◆ Fitting location => Page 24-1 , engine compartment overview
• Connector
• ◆ Black, 4-pin
• ◆ For intake manifold pressure sender and sender for intake air temperature in intake manifold
• ◆ Connector contacts are gold-plated
• ◆ Fitting location => Page 24-1 , engine compartment overview

• 5 Nm
• Crankcase breather hose
• ◆ From oil separator:

=> Repair group 17; Removing and installing parts of lubrication system