Volkswagen Workshop Service and Repair Manuals

Engine code ABD

Servicing upper part

• 5 Nm
• ◆ Install with D6
• Protective cap
• ◆ Only on replacement part for transportation protection of intake air temperature sender, must be removed after installation
• Retainer for injector with intake air temperature sender (G42)*
• ◆ Checking intake air temperature sender
• ◆ Resistance graph
  , Fig. 1
• O ring
• ◆ Renew

• Injector (N30)
• ◆ Checking
• Fuel pressure regulator
• ◆ Checking fuel pressure regulator and holding pressure
• Injection unit upper part
• ◆ Note fitting position
• Seal
• ◆ Renew if damaged
• Fuel return
• Fuel supply
• Plug
• ◆ Release retainers to remove

Servicing lower part

• Throttle valve positioner (V60)*/**
• ◆ With idling switch (F60)*
• ◆ Checking
• ◆ When installing ensure that the idling switch can only be operated via switch plastic plate stop screw.
  If necessary loosen bracket -4- and align.
• ◆ Check idling after renewing the idling switch
  
• 6 Nm
• Idling switch (F60)
• ◆ Checking and adjusting
  
• ◆ Renewing: Renew throttle valve positioner

• Retainer
• ◆ With support for accelerator cable
• ◆ Adjusting accelerator cable

=> Repair group 20; Removing and installing parts of the fuel supply system; Adjusting accelerator cable

• Protective sleeve
• Injection unit lower part
• Limiting screw
• ◆ The screw is sealed at the factory and must not be moved!
• O ring
• ◆ Renew if damaged
• Vacuum connection
• ◆ For intake air preheating
• Retainer
• 3 Nm

• Connection
• ◆ For activated charcoal filter system

=> Repair Group 20; Removing and installing parts of fuel supply system; Removing and installing parts of activated charcoal filter system

• Retaining clip
• ◆ For injection unit upper part
• Throttle valve potentiometer (G69)*
• ◆ Checking
• ◆ Must not be adjusted
• ◆ If defective: renew injection unit lower part

Engine code ABU, AEA

Servicing upper part

• Injection unit upper part
• ◆ Note fitting position
• Fuel pressure regulator
• ◆ Checking fuel pressure regulator and holding pressure => Page 24-89
• O ring
• ◆ Renew
• Securing washer
• ◆ Remove to install O-ring
• Seal
• ◆ Renew
• 5 Nm
• ◆ Install with D6

• Retainer for injector with intake air temperature sender (G42)*
• ◆ Checking intake air temperature sender
• ◆ Resistance graph
  , Fig. 1
• Injector (N30/N181**)
• ◆ Checking
• Fuel supply
• Seal
• ◆ Renew
• Fuel return
• Seal
• ◆ Renew
• Connection

Servicing lower part

• Throttle valve positioner (V60)*/**
• ◆ With idling switch (F60)*
• ◆ Checking
• ◆ When installing ensure that idling switch can only be operated via switch plastic plate with stop screw.
  If necessary loosen bracket -4- and align.
• ◆ Check idling after renewing the idling switch
  
• ◆ With throttle valve positioner sender (G127)*;
  Checking sender
• 6 Nm

• Idling switch (F60)*
• ◆ Checking and adjusting
  
• ◆ Renewing: Renew throttle valve positioner
• Support bracket
• ◆ For accelerator cable
• ◆ Adjusting accelerator cable

=> Repair group 20; Removing and installing parts of the fuel supply system; Adjusting accelerator cable

• Injection unit lower part
• Limiting screw
• ◆ The screw is sealed at the factory and must not be moved!
• 3 Nm
• Retainer

• Vacuum connection
• ◆ For activated charcoal filter system

=> Repair Group 20; Removing and installing parts of fuel supply system; Removing and installing parts of activated charcoal filter system

• Vacuum connection
• ◆ For intake air preheating
• O ring
• ◆ Renew if damaged
• Throttle valve potentiometer (G69)*
• ◆ Checking
• ◆ Must not be adjusted
• ◆ If defective: renew injection unit lower part
• ◆ Contacts gold plated

→ Fig. 1     Resistance graph

The diagram is valid for coolant temperature sender (G62) and intake air sender (G42).

Scale A shows resistance values for temperature range 0...50 °C and scale B the values for temperature range 50...100 °C.

Examples:

• ◆ 30 °C corresponds to a resistance from 1500...2000 ω
• ◆ 80 °C corresponds to a resistance from 275...375 ω