VW Golf manuals

Volkswagen Golf Service & Repair Manual: Removing and installing intake manifold

Special tools and workshop equipment required
Release tool -T10527-
Release tool -T10527/1-
Removing
–  Remove air filter housing → Chapter.
–  Remove noise insulation → General body repairs, exterior; Rep. gr.66.
–  Set drip tray for workshop hoist -VAS 6208- underneath.
–  Drain coolant → Chapter.
The fuel system is pressurised.Risk of injury due to fuel which may spurt out.Wear eye protection.Wear protective gloves.Release pressure: place clean cloth around connection and carefully open connection.
Risk of functional impairment due to soiling → Chapter.
   
–  First press hose connector -1- downwards, and then press release tabs -arrows-.
–  Keep release buttons pressed and pull off hose coupling.
–  Press release tab on hose -2- for activated charcoal filter.
–  Disconnect hose and move it clear.
 

Removing and installing intake manifold

–  Release catch -arrow- and disconnect vacuum hose -1-.
–  Move clear vacuum hose at air pipe -2-.
–  Move clear air hoses at charge air pipe.
–  Detach connector from charge pressure sender -GX26-.
 

Removing and installing intake manifold

–  Release fasteners -arrows- using release tools -T10527- and -T10527/1-.
–  Remove air pipe -1-.
 

Removing and installing intake manifold

–  Unscrew bolt -1-, and release clamps -arrows-.
–  Pull off coolant hoses.
 

Removing and installing intake manifold

–  Separate electrical connectors:
1 -  For activated charcoal filter system solenoid valve 1 -N80-.
3 -  For throttle valve module -GX3-.
4 -  For intake manifold sender -GX9-.
–  The -arrow- in the illustration can be disregarded.
–  Press release buttons and pull off hose -2- for activated charcoal filter.
–  Unclip fuel supply line -5- and coolant line -6- from intake manifold and push them to one side.
 

Removing and installing intake manifold

–  Disconnect connector -1- from fuel pressure sender -G247-.
–  Also disconnect connector from oil pressure switch.
–  Loosen hose clamps -2- and pull off coolant hoses.
 

Removing and installing intake manifold

–  Remove bolts -arrows-.
–  Remove intake manifold -1-.
Installing
Installation is carried out in the reverse order; note the following:
  Note
Renew seals and O-rings.
–  Install noise insulation → General body repairs, exterior; Rep. gr.66.
–  Install air filter housing → Chapter.
–  Replenish coolant → Chapter.
Specified torques
→ Chapter „Assembly overview - intake manifold“
 

Removing and installing intake manifold

Assembly overview - intake manifold
1 -  Coolant pipe Clipped onto intake manifold. Removing and installing coolant pipe → Chapter 2 -  ...

Removing and installing throttle valve module -GX3-
Throttle valve module -GX3- consists of Throttle valve module -J338- Throttle valve drive for electronic power control - ...

Other materials:

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Leaks at shock absorbers
Shock absorbers are often replaced because of externally visible leakage. Inspections on the test rig and in the vehicle have shown that in the majority of cases this replacement is not justified. Slight loss of fluid (“sweating”) at ...

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