Volkswagen Golf Service & Repair Manual: Assembly overview - 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 / Assembly overview - intake manifold

Assembly overview - intake manifold

1 -	Coolant pipe

Clipped onto intake manifold.

Removing and installing coolant pipe → Chapter

2 -	Intake manifold

Combined in one unit with charge air cooler

Removing and installing → Chapter

3 -	Coolant pipe

Clipped onto intake manifold.

4 -

Bolt

Specified torque and tightening sequence → Fig.

5 -

O-ring

Renew

6 -	Intake manifold sender -GX9-

Consisting of

Intake air temperature sensor 2 -G299-

Intake manifold pressure sender -G71-

Removing and installing → Chapter

7 -

Gaskets

Renew

8 -	Charge air pressure sender -GX26-

Consisting of

Charge air pressure sender -G31-

Intake air temperature sender -G42-

Removing and installing → Chapter

9 -

O-ring

Renew

10 -

Union

11 -

O-ring

Renew

12 -

Air pipe

For removal, use release tools -T10527- and -T10527/1-

13 -

O-ring

Renew

14 -

Bolt

Thread-forming

Fit and screw in bolt by hand so that it screws into old thread Then tighten bolt to torque

7 Nm

15 -	Retaining clip

For air pipe.

16 -	Throttle valve module -GX3-

Consisting of

Throttle valve module -J338-

Throttle valve drive for electronic power control -G186-

Throttle valve drive angle sender 1 for electronic power control -G187-

Throttle valve drive angle sender 2 for electronic power control -G188-

Removing and installing → Chapter

Clean → Chapter.

After throttle valve control module -GX3- has been replaced, it must be re-adapted to engine control unit -J623-. Use vehicle diagnostic tester for this.

17 -

Seal

Renew

18 -	Vacuum line

19 -

O-ring

Renew

20 -	Vacuum line

21 -

O-ring

Renew

Intake manifold - specified torque and tightening sequence

–	Tighten bolts in stages as follows:

Assembly overview - intake manifold

Stage	Bolts	Specified torque
1	-arrows-	Starting in centre, screw in bolts alternately by hand until they make contact
2	-arrows-	Starting in centre, screw in bolts alternately: 8 Nm

Intake manifold

...

Removing and installing intake manifold

Special tools and workshop equipment required Release tool -T10527- Release tool -T10527/1- ...

Other materials:

Removing and installing coolant pump
Special tools and workshop equipment required Refractometer -T10007 A- Drip tray for workshop hoist -VAS 6208- Hose clip pliers -VAS 6340- Cooling system charge unit -VAS 6096- Adapter for cooling ...

Removing and installing flywheel
Special tools and workshop equipment required Counterhold -3067- Removing Gearbox removed ...

Adjusting Bowden cable A for entry assistance
Special tools and workshop equipment required Feeler gauges -VAS 5301/10- Adjusting conditions Seat pan and backrest must be padded and bolted together. ...