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

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:

Silicone remover
Designation: Aqueous silicone remover -LSW 019 000 A5- Silicone remover -LVM 020 000 A5- Slow-drying silicone remover -LVM 020 100 A5- Issued 02.2012 ...

Cleaning and changing windscreen wiper blades
Fig. 198 Changing the windscreen wiper blades Fig. 199 Changing the rear window wiper blade First read and observe the introductory information and safety warnings The factory-fitted windscreen wiper blades are coated with graphite. The graphite coating ensures that the windscreen wipe ...

Removing and installing onboard supply control unit -J519-, LHD vehicles
Note When renewing the control unit, select Renew function for the respective control unit in Guided fault finding or Guided functions mode → Vehicle diagnostic tester. Removing � ...