24-16 Fuel Injection–Gasoline

Fuel Injection Components (2.5L)

FUEL INJECTION
COMPONENTS (2.5L)
Component overview (2.5L)
1. Fuel injectors
• Cylinder #1 (N30)
• Cylinder #2 (N31)
• Cylinder #3 (N32)
• Cylinder #4 (N33) N24-10302
• Cylinder #5 (N83)

2. Camshaft position sensor (G40)

3. 81-pin ECM harness connector

• Switch ignition OFF before
disconnecting or connecting.

4. Motronic engine control module

(ECM) (J623)

5. 40-pin ECM harness connector

• Switch ignition OFF before
disconnecting or connecting.

6. Secondary air injection solenoid

valve (N112)
• See 26 Exhaust System.

7. Engine coolant temperature

(ECT) sensor (G62)

8. Evaporative emission (EVAP)

canister purge regulator valve
(N80)
• Arrow points in direction of flow.
9. Ignition coils with power output
stages
• Use ignition coil puller T40039 for
removal. See Spark plugs,
replacing in 03 Maintenance.
10. Mass air flow (MAF) sensor (G70)
• With intake air temperature (IAT)
sensor (G42)
11. E-box in engine compartment
• Secondary air injection pump relay
(J299)
• Fuel pump relay (J17)
• Power supply relay
(terminal 30, B+) (J317)
• Power supply relay (terminal 15)
(J329)
12. Engine speed (rpm) sensor (G28)
• Mounted to control housing cover
13. Throttle valve control module
(J338)
• See Throttle valve, removing
and installing (2.5L) in this repair
group.
14. Camshaft adjustment valve
(N205)
15. Secondary air injection pump
motor (V101)
• See 26 Exhaust System.
16. Knock sensor 1 (G61)
17. Knock sensor 2 (G66)
18. 6-pin harness connector
• Black connector
• For oxygen sensor before catalytic
converter and oxygen sensor
heater
• On bulkhead at left
19. Oxygen sensor (G39) before
catalytic converter
• In exhaust manifold
20. 4-pin harness connector
• Only for engine code BGQ, CBUA
• Black connector
• For oxygen sensor in center of
catalytic converter and oxygen
sensor heater
21. Oxygen sensor in center of
catalytic converter (G465)
• Only for engine code BGQ, CBUA
22. 4-pin harness connector
• Brown connector
• For oxygen sensor behind catalytic
converter and oxygen sensor
heater 1
23. Oxygen sensor behind catalytic
converter (G130)
 Fuel Injection–Gasoline 24-17
Fuel Injection Components (2.5L)

Component locations (2.5L)

For more component location information, including fuses and
relays, see 97 Fuses, Relays, Component Locations.

½ Underneath engine, lower engine compartment sound absorber

VJ0697022a panels removed:
1. Radiator outlet hose coolant temperature sensor (G83)
2. Engine cooling fan electric connector block
3. Engine speed sensor (G28) and connector

½ At front of engine (engine removed from vehicle for clarity):

1. Manifold absolute pressure (MAP) sensor (G71)
2. Engine oil pressure sensor (F1)
3. Secondary air pump (V101)

VJ0697020

½ Engine coolant temperature (ECT) sensor (arrow) on bottom left of

radiator at hose connection.

0024806a
24-18 Fuel Injection–Gasoline
Fuel Injection Components (2.5L)

Intake manifold overview

(2.5L)
1. Bleeder hose for crankcase
ventilation
• From cylinder head cover

2. Ventilation hose

3. Evaporative emission (EVAP)

canister purge regulator valve N24-10306
(N80)

4. Vacuum hose
• From leak detection pump (V144)

5. Bolt
• Tighten to 9 Nm (80 in-lb)
• Check tightening torque on 2005
models when performing first
spark plug change. See
03 Maintenance.

6. Fuel rail

7. Fuel supply line

8. Gasket
• Replace with new.
• Installation position: flashing faces
up

9. Intake manifold

10. Rubber bushing

• Engine codes BGP, BGQ only

11. Intake manifold support 19. Throttle valve control module

(J338)
12. Bolt • Also contains the following
• Tighten to 25 Nm (18 ft-lb) electronic power control
13. Nut/Bolt components:
-Throttle drive (G186)
• BGP, BGQ nut:
-Throttle drive angle sensor 1
Tighten to 20 Nm (15 ft-lb)
(G187)
• CBTA, CBUA bolt:
-Throttle drive angle sensor 2
Tighten to 16 Nm (12 ft-lb)
(G188)
14. O-ring • During replacement, erase
• Replace if damaged. adaptation values and adapt ECM
to throttle valve control module
15. Manifold absolute pressure using Volkswagen scan tool or
(MAP) sensor (G71) equivalent.
16. Screw 20. Oil seal
• Tighten to 3.5 Nm (31 in-lb) • Replace if damaged.
17. Coolant connections

18. Bolt
• Tighten to 6.5 Nm (57 in-lb)
 Fuel Injection–Gasoline 24-19
Fuel Injection Components (2.5L)

Intake manifold, removing and installing (2.5L)

WARNING —
• To avoid personal injury, be sure the engine is cold before
VJ0624011 beginning this procedure.

– Disconnect battery ground strap from battery negative (–) terminal.

See 27 Battery, Alternator, Starter.

– Remove engine cover. See 03 Maintenance.

½ Disconnect vent line (A), breather line (B) and fuel supply line (C).
Press in securing ring to disengage lines.

WARNING —
• Before opening the fuel system, wrap shop towels around
connections and loosen connections slowly to release
pressure.

VJ0624012
½ Disconnect harness connectors (A).
– Remove wiring harness (B) from retaining brackets.

– Release clamps and retaining ring (C) out of retainer.

– Remove two bolts (arrow) and remove retaining bracket.

– Remove throttle valve. See Throttle valve, removing and

installing (2.5L) in this repair group.

½ Disconnect harness connector (A) and crankcase ventilation hose

(C).

– Remove wiring harness (B) by carefully prying off clips (arrows).

VJ0624013

1
½ Pull oil dipstick (1) out and press retaining ring (4) downward.
– If present, remove nuts (3) on intake manifold support.

– Unscrew guide tube (2) at bottom of cylinder block and pull it out.
M24-0522
4 2

3 M24-0522
24-20 Fuel Injection–Gasoline
Fuel Injection Components (2.5L)

½ Loosen intake manifold bolts (arrows) using multipoint socket

T10107A T10107 A or equivalent. Bolts remain in intake manifold.

– Tilt intake manifold and lift out.

M24-0510
CAUTION—
• Make sure that no bolts fall out.

– Plug intake channels in cylinder head using clean rags.

– Insert oil dipstick guide tube into cylinder block again and fasten it.

– If intake manifold is being replaced, remove fuel rail with injectors.

See Fuel injectors, removing and installing (2.5L) in this repair
group.
M24-0510
– Disconnect vacuum hose for leak detection pump (LDP).

– Remove manifold absolute pressure (MAP) sensor.

– Remainder of installation is reverse of removal.

• Be sure to replace seals between intake manifold and cylinder
head.
• Tighten all bolts for intake manifold from inside to outside in a
diagonal sequence.

Tightening torques
Intake manifold support to cylinder block 25 Nm (18 ft-lb)
Intake manifold to cylinder head 9 Nm (80 in-lb)
Manifold absolute pressure sensor to intake 3.5 Nm (31 in-lb)
manifold
Transport strap to cylinder head 25 Nm (18 ft-lb)

Fuel rail and injectors (2.5L)

1. Fuel rail mounting bolts
• Tighten to 3.5 Nm (31 in-lb)
2. Fuel rail
N24-10305
3. Fuel supply line
4. O-ring
• Replace with new.
• Moisten with clean engine oil.
5. Retaining clip
• Make sure clip is correctly seated on fuel injector and fuel
distributor.
6. Fuel injector
• Cylinder #1 (N30)
• Cylinder #2 (N31)
• Cylinder #3 (N32)
• Cylinder #4 (N33)
• Cylinder #5 (N83)
7. Intake manifold
8. Protective cap
9. Breather valve
 Fuel Injection–Gasoline 24-21
Fuel Injection Components (2.5L)

Fuel injectors, removing and installing (2.5L)

– Disconnect battery ground strap from battery negative (–) terminal.

VJ0624011
– Remove engine cover. See 03 Maintenance.

½ Disconnect vent line (A), breather line (B) and fuel supply line (C).
Press in securing ring to disengage lines.

WARNING —
• Before opening the fuel system, wrap shop towels around
connections and loosen connections slowly to release
pressure.

½ Disconnect harness connectors (A).

– Remove wiring harness (B) from retaining bracket.

VJ0624012
– Pull clamps and retaining ring (C) out of retainer.

– Remove two bolts (arrow) and remove transport strap.

– Remove fuel rail mounting bolts and pull fuel rail with injectors
uniformly out of intake manifold.

– Plug openings in intake manifold or cover it.

– Pull off retaining clip for each fuel injector. Remove fuel injectors
from fuel rail.

– When installing, coat new fuel injector O-rings lightly with clean
motor oil.

½ Press fuel injectors into fuel rail so that tabs (1) and (2) face each
other.

– Push retaining clip (3) into groove of fuel injector, as shown.

M24-0514
– Position shoulder (4) correctly in cutout of retaining clip on both
sides.

– After assembly, verify that all fuel injectors are securely seated.

– Set fuel rail with secured fuel injectors onto intake manifold and
uniformly press it into place.

– Install fuel rail mounting bolts and tighten to specification.

Tightening torque
Fuel rail to intake manifold 3.5 Nm (31 in-lb)

– Install remaining components and harness connectors in reverse

order of removal.

– Connect battery, see 27 Battery, Alternator, Starter.

– If fuel injectors were replaced, erase adaptation values and adapt

engine control module using Volkswagen scan tool or equivalent.
24-22 Fuel Injection–Gasoline
Fuel Injection Components (2.5L)

Throttle valve, removing and installing (2.5L)

NOTE —
• The throttle valve is also referred to as throttle valve control
0024819 module (J338).

– Remove engine cover. See 03 Maintenance.

½ Disconnect secondary air injection hoses (lower arrows) from

intake air duct (1).

– Release spring clamp (upper arrow) and remove intake air duct (1).

½ Unscrew (arrows) and remove intake air connection at engine hood

lock carrier.

0024820

½ Disconnect harness connector (1) and vent hose (2) from throttle
valve.

– Remove throttle valve mounting bolts (arrows) and pull throttle

valve away from intake manifold.

0024821 CAUTION—
• Plug intake manifold port using a clean rag.

½ Pinch off coolant hoses with hose clamps 3094 or equivalent. Pull
coolant hoses (arrows) off throttle valve.
3094
– Installation is reverse of removal. Replace seal for throttle valve
M24-0517 control module if damaged.

Tightening torque
Throttle valve to intake manifold 6.5 Nm (58 in-lb)

– Make sure secondary air hoses are securely connected to intake air
duct.

– If throttle valve control module is replaced, erase adaptation values

M24-0517 and adapt ECM to throttle valve control module using Volkswagen
scan tool or equivalent.
 established 1950
Automotive Reference™

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.com

Volkswagen Jetta (A5)

Service Manual: 2005-2010
1.9L and 2.0L diesel, 2.0L and 2.5L gasoline
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• Maintenance procedures from oil changes to belt
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• Engine and cylinder head service, including timing belt
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Tensioner being rotated
• Removal and installation of Motronic (gasoline) and diesel to remove ribbed belt.
fuel injection system components, including Pumpe Düse 03 Maintenance

(PD) and common rail diesel.

• Emission control tests, repairs and adjustments, including
exhaust gas recirculation and secondary air injection system.
• Drivetrain maintenance, troubleshooting, adjustment and
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46 Brakes–Mechanical
• Heating and air-conditioning repair, including A/C
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• 2.0L TSI turbo gasoline (engine code: CBFA, CCTA)
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• Volkswagen OBD II diagnostic trouble codes, SAE-defined • 0A4 5-speed manual
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