Volkswagen Passat B6 2005 - B6 - UA VW Clubdoc.vwclub.org.ua/injector/mono/b6_24_motronic_med_9_1.pdfVolkswagen Passat B6 2005 - > (B6) components a voltage of at least 11.5 V is necessary

Fuel injection system

General notes on fuel injection 24-1, General notes on fuel injection

Safety precautions 20-1, Safety precautions

Rules of cleanliness 24-1, Rules for cleanliness

Technical data 24-1, Technical data

Intake manifold, assembly overview 24-1, Intake manifold, assembly overview

Fuel rail, assembly overview 24-1, Fuel rail, assembly overview

Air filter, assembly overview 24-1, Engine cover/air filter, assembly overview

Intake manifold, removing and installing 24-1, Intake manifold, removing and installing

Fuel injectors, removing and installing 24-1, Fuel injectors, removing and installing

Replace Teflon sealing ring on fuel injector 24-1, Teflon sealing ring on fuel injector, replacing

General notes on fuel injection

Fuel hoses in engine compartment may only be secured with spring-type clamps appropriate for the model type. The use of clamp or screw type clips is not permissible.

Ignition must be switched off when disconnecting the battery. Obtain radio code for radios with anti-theft coding before disconnecting battery.

Observe safety precautions after connecting battery

.

Repair Manual, Electrical Equipment, Repair Group 27, Disconnecting and connecting battery

For trouble-free operation of the electrical

Volkswagen Passat B6 2005 - >(B6)

components a voltage of at least 11.5 V is necessary.

Do not use sealants containing silicone. Particles of silicone drawn into engine, will not be burnt in the engine and damage the oxygen sensor.

If engine only starts briefly and then turns off again after troubleshooting, repair or checking of components, it may be that the immobilizer is blocking the Engine Control Module (ECM). Control module must then be adapted if necessary.

To conclude work, check DTC memory of Engine Control Module (ECM), erase all DTC entries which may have occurred during the tests and repairs. If DTC memory was erased, generate readiness code

Vehicle Diagnosis, Testing and Information System VAS 5051 "Guided Function" .

Vehicles with an airbag are equipped with a crash fuel shut-off system. It reduces the danger of a fire in a crash as the fuel pump is switched off via fuel pump relay.

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 20-1, Safety precautions

Rules of cleanliness 24-1, Rules for cleanliness

Technical data 24-1, Technical data

Rules for cleanliness

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

Thoroughly clean all connections and the surrounding area before disconnecting.

Place parts that have been removed on a clean surface and cover them. Do not use fluffy cloths!

. 2 24Fuel injection system

Carefully cover over opened components or seal, if repairs are not performed immediately.

Only install clean components: Only unpack replacement parts immediately prior to installation. Do not use parts that have been stored loose (e.g. in tool boxes etc.).

When the system is open: Avoid working with compressed air if possible. Do not move vehicle unless absolutely necessary.

Technical data

Engine code BPY

Idle test

Engine idle speed 1) RPM 620 to 800

Engine control module

System designation Motronic MED 9.1

Replacement part number ETKA (electronic parts catalog)

Engine speed (RPM) limitation RPM approx. 6800 Fuel pressure

Low pressure bar approx. 4.0 to 6.0

High pressure bar approx. 40 to 120

1) If voltage supply of Engine Control Module (ECM) drops below 12 volts, idle speed is raised in stages up to 990 RPM. Idle speed is not adjustable.

Intake manifold, assembly overview


10 Nm

Retaining clip

3 Nm

Stud bolt, 10 Nm

Gasket

Replace

Intake manifold

With intake manifold flaps

Coupling rod

Intake Flap Motor V157 with Intake Manifold Runner Position Sensor G336


7 Nm

To EVAP canister

Hose

Evaporative Emission (EVAP) Canister Purge Regulator Valve N80

Hose

Double check valve

Checking 24-2, Components, checking

Intake manifold support

25 Nm

10 Nm

Bonded rubber bushing

Throttle valve control module J338

With Throttle Drive (for Electronic Power Control (EPC)) G186 , Throttle Drive Angle Sensor 1 (for Electronic Power Control (EPC)) G187 and Throttle Drive Angle Sensor 2 (for Electronic Power Control (EPC)) G188

Removing and installing 24-1, Throttle Valve Control Module J338 , removing and installing

7 Nm

Seal

Replace if damaged

5 Nm

Intake Air Temperature (IAT) Sensor G42


10 Nm

Fuel rail, assembly overview

Warning!

Follow safety measures for releasing fuel pressure in high pressure area 20-1, Releasing fuel pressure in high pressure area

Cylinder 1 Fuel Injector N30 to Cylinder 4 Fuel Injector N33

Removing and installing 24-1, Fuel injectors, removing and installing

5 Nm

Fuel rail

Plate nut

Pressure relief valve

30 Nm


To remove and install, remove intake manifold 24-1, Intake manifold, removing and installing

Fuel line

Do not install when under tension

Tighten union nut to 20 Nm

Bracket

Fuel line

Do not install when under tension

Tighten union nut on fuel rail to 25 Nm.

Connector

For fuel injectors

7 Nm

Fuel Pressure Sensor G247

20 Nm

Removing and installing 24-1, Fuel Pressure Sensor G247 , removing and installing

Engine cover/air filter, assembly overview


Mass air flow (MAF) sensor G70

3 Nm

Upper section of air filter/engine cover

Spring-type clip

Intake air guide

Filter element

Air filter lower part

3 Nm

Heat shield

Rubber boot

Note installation marking


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Intake tube

Note installation marking

Engine cover/air filter, removing and installing

- Disconnect intake duct - 1 - .

- Disconnect connector - 2 - .

- Remove bolts - 3 - .

- Remove engine cover upward in sequence - A to D - at places shown.

Installing

- Ensure rubber bearings - arrows - are inserted in engine cover.

- Position engine cover in installation position and press rubber bearings onto anchor screws at the same time.

Installation is performed in reverse order of removal.

Air filter element, removing and installing


Removing

- Remove engine cover/air filter 24-1, Engine cover/air filter, removing and installing .

- Remove intake air guide - arrow - .

- Remove all screws - arrows - .

- Separate engine cover, paying attention to retainers - arrows - .


- Pull air filter element out of engine cover.

Air filter insert, installing

Note:

Always use an original equipment air filter element.

Air filter housing must be clean.

Note the following when blowing out the air filter housing with pressurized air: To avoid malfunctions, cover Mass Air Flow (MAF) Sensor G70 with a clean cloth.

- Check Mass Air Flow (MAF) Sensor G70 and intake duct Item - 5 - for salt residue, dirt and leaves.

- Ensure air filter element is properly centered when placed into the mounting of the lower part of air filter housing.

- Set upper part of air filter housing onto lower part of air filter housing, without using much force. When doing this, make sure that the upper part of air filter housing is not placed crooked onto air filter element (observe sealing lip of air filter element).

Installation is in reverse order or removal.

Throttle Valve Control Module J338 , removing and installing

Removing

- Remove engine cover/air filter 24-1, Engine cover/air filter, removing and installing .

- Remove insulation pan


.

Repair Manual, Body Exterior, Repair Group 50, Front body; assembly overview of noise insulation

- Loosen bolts and clamps - arrows - and remove charge air pipe and hose downward.

- Remove four bolts on Throttle Valve Control Module J338 and remove it.

Installing

Installation is in reverse order of removal. Note the following:

- If a new Throttle Valve Control Module J338 was installed, adapt engine control module do it Vehicle Diagnosis, Testing and Information System VAS 5051 "Guided Functions" .

Intake manifold, removing and installing

Warning!


Removing

Note:

Observe safety precautions 20-1, Safety


precautions

Observe rules for cleanliness 24-1, Rules for cleanliness

If a fuel injector was pulled out of cylinder head when removing the intake manifold, the Teflon sealing ring must be replaced 24-1, Teflon sealing ring on fuel injector, replacing

Intake manifold, assembly overview 24-1, Intake manifold, assembly overview

- Remove Throttle Valve Control Module J338 24-1, Throttle Valve Control Module J338 , removing and installing .

- Disconnect all electrical harness connectors necessary.

- Disconnect vacuum hose between intake manifold and vacuum pump from intake manifold.

Warning!

For reasons of safety, remove Fuse 34 (on fuse panel D) SD34 for Fuel Pump (FP) from fuse holder in instrument panel on right side before opening the fuel supply system, as the FP may be activated by the drivers door contact switch.

Fuel supply line is under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.


- Disconnect vacuum line - 1 - ventilation line - 2 - and fuel line - 3 - . To do so, press release buttons.

Disconnect vacuum lines - arrows - from intake manifold and from cylinder head cover.

- Disconnect both fuel lines from high pressure pump.

- Remove coolant pipe and oil dipstick guide from intake manifold - arrows - and pull off oil dipstick guide upward from engine.


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

- Remove all bolts from intake manifold.

- Carefully pull off intake manifold with fuel rail from cylinder head.

Installing


If a fuel injector was pulled out of cylinder head when removing the intake manifold, replace Teflon sealing ring of fuel injector 24-1, Teflon sealing ring on fuel injector, replacing .

Replace O-rings between fuel injectors and fuel rail and coat them lightly with clean motor oil.

Position intake manifold with fuel rail on cylinder head and press evenly onto fuel injectors.

If Intake Flap Motor V157 or intake manifold was replaced, Intake Manifold Runner Position Sensor G336 must be adapted to ECM Vehicle Diagnosis, Testing and Information System VAS 5051 "Guided Functions" .

Torque specifications Nm

Mounting bolts for intake manifold 10

Bolt for intake manifold support 23

Nut for intake manifold support 10

Fuel supply line to high pressure pump 25

Fuel return line to high pressure pump (replace banjo fitting) 17

Bolts for Intake Flap Motor V157 7


Fuel rail, removing and installing

- Remove intake manifold 24-1, Intake manifold, removing and installing .

- Remove hoses from EVAP canister.

- To do so, open hose clamp - 1 - .

- Loosen two fuel rail bolts - arrows - .

- Remove hose connection - 1 - from intake manifold and loosen both bolts - arrows - .

- Loosen union nuts of both fuel lines - 2 and 3 - .

- Carefully pry off linkage from Intake Flap Motor V157 - 4 - .

- Remove Intake Flap Motor V157 - 5 - .


- Remove fuel rail from intake manifold.

- Installation is in reverse order of removal.

Tightening torques 24-1, Fuel rail, assembly overview

Fuel Pressure Sensor G247 , removing and installing

Special tools, testers and auxiliary items required

Assembly tool T10118

Socket wrench insert 27 mm VAS 5301/7

Warning!


Removing:


- Disconnect coolant pipe and oil dipstick guide from intake manifold - arrows - and pull off oil dipstick guide upward from engine.

- Disengage connector from Fuel Pressure Sensor G247 using assembly tool T10118 .

- Remove Fuel Pressure Sensor G247 using socket wrench insert 27 mm VAS 5301/7 .

Installing:


Tightening torque 24-1, Fuel rail, assembly overview

Fuel injectors, removing and installing


Tool set T10133


Fuel injector, individual parts

Radial compensation (replace) Combustion chamber sealing ring (Teflon sealing ring), replace, the ring must not be greased or handled with any other lubricants when installing. Groove on fuel injector Support washer (replace) O-ring (replace, coat lightly with clean engine oil when installing) Support ring

Removing:

- Remove intake manifold 24-1, Intake manifold, removing and installing .

- Seal intake channels with a clean cloth.

- Bend retaining tabs of radial compensation to the side using a screwdriver and pull off support ring from fuel injector.

Note:

Radial compensation retaining tabs are destroyed by this (retaining tabs break). If fuel injector is re-


installed, radial compensation must be replaced.

- Screw hammer T10133/3 to puller T10133/2 . Then guide puller T10133/2 into groove on fuel injector and carefully tap fuel injector out.

Installing:

Note:

The Teflon sealing ring of fuel injector may not be oiled or greased.

Possibly an opened intake valve hinders the cleaning. In this case, engine must be turned further by hand using a socket wrench on the crankshaft.

- Thoroughly clean bores for high pressure fuel injectors in cylinder head using nylon brush T10133/4 .

- Replace O-ring and Teflon sealing ring of fuel injector 24-1, Teflon sealing ring on fuel injector, replacing .


- Using assembly drift T10133/9 , press fuel injector into hole in cylinder head until it stops.

- Make sure fuel injectors are positioned correctly in cylinder head.

Teflon sealing ring on fuel injector, replacing


Tool set T10133

Note:

Teflon sealing ring must not be oiled.


- Clean fuel injector in area of sealing ring - arrow - . Remove any deposits (coking) using a brass brush.

- Carefully cut sealing ring using a knife.

- Clean sealing ring groove.

- Insert a new sealing ring on to assembly cone T10133/5 . Slide sealing ring as far as it will go on to assembly cone T10133/5 using assembly sleeve T10133/6 .

- Rotate assembly sleeve T10133/6 and slide sealing ring on to assembly cone T10133/5 up to end.


- Place assembly cone T10133/5 on to fuel injector and slide sealing ring on to fuel injector using assembly sleeve T10133/6 .

- Remove assembly cone T10133/5 and slide sealing ring into groove using assembly sleeve T10133/6 .

- Press calibrating sleeve T10133/7 using a gentle turning motion (approx. 180 ) on to fuel injector until it stops.

- Pull off calibrating sleeve T10133/7 again using turning motion in opposite direction.

- Press calibrating sleeve T10133/8 using a gentle turning motion (approx. 180 ) on to fuel injector until it stops.


- Pull off calibrating T10133/8 again using turning motion in opposite direction.

- Replace O-ring on fuel injector and support washer.

- Install fuel injector again with support ring - 1 - and clip in radial compensation - 2 - on support ring.


24 - 2

Components, checking

Checking double check-valve


Hand vacuum pump VAS 6213

- Disconnect connectors from Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 and Low Fuel Pressure Sensor G410 - arrows - .

- Disconnect Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 - B - from hose - A - .

. 1 2Components, checking

- Set slide ring - 1 - on hand vacuum pump VAS 6213 to position - A - for "vacuum" .

- Connect hand vacuum pump VAS 6213 on hose to double check-valve - arrow - .

- Operate hand vacuum pump VAS 6213 several times, vacuum must build up.

If no vacuum builds up, replace double check-valve.

. 2 2Components, checking

24 - 3

Engine control module (ECM)

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

Engine Control Module (ECM) secured with anti-theft immobilizer, removing and installing 24-3, Engine Control Module (ECM) secured with anti-theft immobilizer, removing and installing

Engine Control Module (ECM), removing and installing

Note:

If it is desired to replace Engine Control Module (ECM), connect Vehicle Diagnosis, Testing and Information System VAS 5051 and perform guided function "Replace Engine Control Module (ECM)" .

Caution!

On vehicles with heavy duty suspension, vehicle must be limited to a maximum speed of 210 km/h with the engine control module. At speeds above 210 km/h, damage to input shafts can occur. Perform Guided Function "Limit Maximum Speed" using the Vehicle Diagnostic, Testing and Information System VAS 5051B .

Removing

- Switch off ignition.

- Remove windshield wiper arms and plenum chamber cover

.

Repair Manual, Electrical Equipment, Repair Group 92,

- Disconnect harness connector - 1 - from Heated Windshield Control Module J505 .

. 1 8Engine control module (ECM)

- Slide connector release catches - 2 - on Engine Control Module (ECM) outward and disconnect both harness connectors.

- Remove mounting bolts - 3 - .

- Remove mounting frame with Engine Control Module (ECM) from plenum chamber.

- Press release catches - 1 - outward and slide Engine Control Module (ECM) - 2 - from mounting frame.

Installing

- Slide Engine Control Module (ECM) - 1 - into mounting frame in direction of - arrow - .


Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru Volkswagen, Skoda, Seat, Audi

- Place mounting frame with Engine Control Module (ECM) on to bracket - 4 - .

Tightening torque of mounting nuts for bracket: 6 Nm.

- Tighten mounting bolts - 3 - to 7 Nm.

- Connect harness connectors to Engine Control Module (ECM) and slide release catches - 2 - inward.

- Connect harness connector - 1 - to Heated Windshield Control Module J505 .

- Install plenum chamber cover

.

Repair Manual, Body Exterior, Repair Group 64, Removing and installing plenum chamber cover

- Install windshield wiper arms

.

Repair Manual, Electrical Equipment, Repair Group 92, Front windshield wiper system; removing and installing wiper arms

Engine Control Module (ECM) secured with anti-theft immobilizer, removing and installing

Note:

If it is desired to replace Engine Control Module (ECM), connect Vehicle Diagnosis, Testing and Information System VAS 5051B and perform guided function "Replace Engine Control Module (ECM)" .


Caution!

On vehicles with heavy duty suspension, vehicle must be limited to a maximum speed of 210 km/h with the engine control module. At speeds above 210 km/h, damage to input shafts can occur. Perform Guided Function "Limit Maximum Speed" using the Vehicle Diagnostic, Testing and Information System VAS 5051 .


Hot air gun from wiring harness repair kit VAS 1978

Attachment nozzle from wiring harness repair kit VAS 1978

Removing

- Switch off ignition.

- Remove windshield wiper arms

.


- Remove plenum chamber cover

.



Note:

Thread of shear bolts is equipped with locking compound. By heating the shear bolts using a hot air gun, inhibition effect of the locking compound is lowered.

Caution!

Cover wires, harness connectors and control modules in the close vicinity of Engine Control Module (ECM) to prevent damage from burning.

Perform adjustments on hot air gun - 4 - as shown:

- Turn potentiometer for temperature adjustment - 2 - to maximum heat output (600 C).

- Move two stage switch for air quantity - 3 - to position 3.

Warning!

By heating the shear bolts, parts of the protective housing are heated intensely. Wear protective gloves to prevent injuries.

- Guide nozzle of hot air gun on to shear bolts.

- Switch hot air gun on and warm bolts.

- Remove shear bolt - 2 - using pliers on bolt head.

The procedure for the second shear bolt is exactly the same.


- Disconnect harness connector - 1 - from Heated Windshield Control Module J505 .

- Lift cover - 1 - and pull it forward.

- Slide connector release catches - 1 - on Engine Control Module (ECM) outward and disconnect both harness connectors.

- Remove mounting frame with Engine Control Module (ECM) from plenum chamber.


- Press release catches - 1 - outward and slide Engine Control Module (ECM) - 2 - from mounting frame.

Installing

- Slide Engine Control Module (ECM) - 1 - into mounting frame in direction of - arrow - .

- Place mounting frame with Engine Control Module (ECM) on to bracket in plenum chamber.

Tightening torque of mounting nuts for bracket: 6 Nm.

- Connect harness connectors to Engine Control Module (ECM) and slide release catches - 1 - inward.


- Slide cover - 1 - over Engine Control Module (ECM) and press it downward.

- Tighten new shear bolts - 2 - uniformly until bolt heads shear off.

- Connect harness connector - 1 - to Heated Windshield Control Module J505 .

- Install plenum chamber cover

.


- Install windshield wiper arms

.



24-01.pdf24-02.pdf24-03.pdf

Documents

Volkswagen Passat B6 2005 - B6 - UA VW Clubdoc.vwclub.org.ua/injector/mono/b6_24_motronic_med_9_1.pdfVolkswagen Passat B6 2005 - > (B6) components a voltage of at least 11.5 V is necessary