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:

Assembly overview - speed sensor on rear axle, front-wheel drive
1 -  ABS speed sensor Clean inside surface of hole before inserting sensor Coat inside surface with high-temperature paste -G 052 112 A3- Removing and installing → Chapter 2 -  Bolt ...

Removing and installing brake caliper
Special tools and workshop equipment required     Torque wrench -V.A.G 1331-   Brake pedal depressor -V.A.G 1869/2- & ...

Removing and installing Valeo heat exchanger, RHD vehicles
Special tools and workshop equipment required     Drip tray for workshop hoist -VAS 6208-   Hose clamps up to 25 mm -3094- ...

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