Safety precautions

WARNING: This page does not describe the selected car, but rather 14 other vehicles, including the 2005 Volkswagen GTI, 2004 Volkswagen R32, 2004 Volkswagen Jetta, 2004 Volkswagen GTI, and 2003 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

WARNING:

Observe the following for all installations, especially in engine compartment due to lack of room:

Route lines of all types (e.g. for fuel, hydraulic, EVAP canister system, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed.
Watch for sufficient clearance to all moving or hot components.

If special testing equipment is required during road test, note the following:

Test equipment must always be secured to the rear seat and operated from there by a second person.

If test and measuring equipment is operated from the passenger seat, the person seated there could be injured in the event of an accident involving deployment of the passenger-side airbag.

To reduce the risk of personal injury and/or damage to the fuel injection and ignition system, always observe the following:

Do not touch or disconnect ignition wires when engine is running or turning at starting RPM.
Only disconnect and reconnect wires for injection and ignition system, including test leads, when ignition is switched off.
If engine is to be cranked at starting RPM without starting:

Vehicles with engine code AFP

Fig 1: 5-Pin Connector At Ignition Coil N152

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect 5-pin connector from Ignition Coil -N152- (arrow).

Fig 2: Identifying Main Fuse Panel

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove fuse 32 from fuse holder.

NOTE: By removing fuse 32, voltage supply to the fuel injectors is interrupted.

Vehicles with engine codes BDF and BJS

Remove engine cover.

Fig 3: Identifying Assembly Tool T10118 On Release Button

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect connector from ignition coils 1 to 6.

Assembly tool T10118 is recommended to release connector catches.

To do so, attach assembly tool T10118 on locking button -arrow- and then carefully pull down connector.

NOTE: Before disconnecting harness connectors, mark allocation to component.

Fig 4: Identifying Main Fuse Panel

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove fuse 29 from fuse holder.

NOTE: By removing fuse 29, voltage supply to the fuel injectors is interrupted.