Volkswagen 2004 Golf User Manual

24 - 1 Fuel injection system General notes on fuel injection 24-1, General Notes on Fuel Injection Safety precautions 24-1, Safety precautions R

Mass Air Flow (MAF) sensor G70 3 Nm Upper section of air filter/engine cover Spring clip Intake air guide Filter element Lower part of

Disassembling- Remove intake air guide. - Remove bolts - arrows - . - Separate engine cover, note locking mechanism - arrows - . Throttle Valve

- Remove line - A - and hose - B - - arrows -. - Loosen bolts - arrows - and remove charge air pipe with hose downward. - Remove four bolts of Thr

Note:  Observe safety precautions 24-1, Safety precautions  Observe the rules for cleanliness 24-1, Rules of cleanliness  Always replace

goggles and protective clothing to prevent injuries and contact with skin. Before loosening hose connections, place rags around the connection p

- Remove intake manifold support - arrows - and disconnect connector - 1 - from Fuel Pressure Sensor G247 . - Remove all bolts from intake manifold.

- To do so, open hose clamp - 1 - . - Loosen two bolts - arrows - of fuel rail. - Disconnect hose connection - 1 - from intake manifold and loos

Fuel Pressure Sensor G247 , removing and installing Special tools, testers and auxiliary items required Assembly tool T10118  Socket wrench in

Fuel injectors, removing and installingSpecial tools, testers and auxiliary items required Tool set T10133 Fuel injector, individual parts 

- Bend retaining tabs of radial compensation to side using a screwdriver and pull off support ring from fuel injector.- Screw hammer T10133/3 to p

of at least 11.5 V is required.  Do not use any silicone sealant. Traces of silicone components which are sucked into the engine are not burned the

- Thoroughly clean bores for high pressure fuel injectors in cylinder head using nylon brush T10133/4 . - Replace O-ring and Teflon sealing ring

 Tool set T10133 Note:  Teflon sealing ring must not be oiled. - Thoroughly clean fuel injector in area of sealing ring - arrow - . Remove

- Insert a new sealing ring on to assembly cone T10133/5 . Slide seal with assembly sleeve T10133/6 as far as possible onto assembly cone T10133

motion (approx. 180 ) on to fuel injector until it stops. - Pull off calibrating sleeve T10133/7 again using turning motion in opposite directio

24 - 2 Components, checking Checking double check-valve 24-2, Double check-valve, checking Double check-valve, checking Special tools, testers

- Connect Hand vacuum pump VAS 6213 on hose to double check-valve - arrow - . - Operate hand vacuum pump VAS 6213 several times, vacuum must build u

24 - 3 Engine Control Module (ECM) Engine Control Module (ECM), removing and installing 24-3, Engine Control Module (ECM), removing and installing

- Disengage forward harness connector - 1 - from Engine Control Module (ECM) and disconnect it. - Pry up locking mechanism - 2 - slightly. - Slide E

 Electric cutter V.A.G 1561 A  Saw set V.A.G 1561/14  Locking pliers Note: If replacing Engine Control Module (ECM), connect Vehicle Diagn

- Saw into heads of shear bolts so that two parallel surfaces result - arrows - . - Remove bolts using locking pliers . - Insert a screwdriver -

clothing to prevent injuries and contact with skin. Before loosening the fuel line, place a rag around the connection point. Then release pressure b

- Disengage forward harness connector - 1 - from Engine Control Module (ECM) and disconnect it. - Pry up locking mechanism - 2 - slightly. - Slide

. Repair Manual, Electrical Equipment, Repair Group 92, Windshield wiper system, removing and installing windshield wiper system DTC memory of

Select mode of operation:- Press "Vehicle Self-Diagnosis" selection on display. Select vehicle system:- Press "01 - Engine Electronic

the original path is followed. To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot components. If specia

Idle test Idle speed 1) 1 RPM 620 to 800Engine Control Module (ECM) 2) System identification Motronic MED 9.1 Replacement part number E

10 Nm Screw clip 3 Nm Stud bolt, 10 Nm Gasket  Replace Intake manifold  With intake manifold flaps Coupling link Intake Flap Motor

7 Nm To EVAP canister Hose Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 Hose Double check-valve  Checking 24-2, Compo

Cylinder 1 Fuel Injector N30 to Cylinder 4 Fuel Injector N33  Removing and installing 24-1, Fuel injectors, removing and installing 5 Nm Fue

Bracket Fuel line  Do not install when under tension Tighten union nut on fuel rail to 25 Nm. Connector  for injectors 7 Nm Fuel Pres