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

Volkswagen Golf Service & Repair Manual / 4- cylinder injection engine(1.4 1 direct inction. turbocharger) / Mixture preparation system, electronic inj., Gas / Intake manifold / 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

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Removing and installing throttle valve module -GX3-

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