Volkswagen Workshop Service and Repair Manuals

Removing and installing air cleaner , Fig. 3

• 3 Nm
• ◆ Notes on installing => Page 24-27
• Plug
• ◆ Note installation position
• Crankcase breather hose
• ◆ From oil separator:

=> Repair group 17; Removing and installing parts of lubrication system

• Air cleaner upper part
• Filter element

• Air cleaner lower part
• Seal
• ◆ Check securely seated
• ◆ Renew if damaged
• Connecting hose
• Warm air intake hose
• ◆ From warm air collector plate:

=> Repair group 26; Removing and installing parts of exhaust system

• Air intake housing with regulating flap
• ◆ Check intake air preheating => Page 24-91
• 5 Nm
• Connecting piece for cold air intake
• ◆ Additionally secured on body with retaining clip

→ Fig. 1     Resistance values for coolant temperature sender (G62)

The diagram is divided into two temperature ranges:

•      A -     From 0...50 °C
•      B -     From 50...105 °C

Examples:

• ◆ 30 °C is in range A and corresponds to a resistance of 1.5...2.0 kω
• ◆ 80 °C is in range B and corresponds to a resistance of 275...375 ω

→ Fig.2     Resistance values for intake air temperature sender (G42)

The diagram is divided into two temperature ranges:

•      A -     From 0...50 °C
•      B -     From 50...105 °C

Examples:

• ◆ 20 °C is in range A and corresponds to a resistance of 2.3...2.6 kω
• ◆ 80 °C is in range B and corresponds to a resistance of 290...330 ω

→ Fig. 3     Removing and installing air cleaner

Removing

• ‒ Remove cover above camshaft housing.
• ‒ Remove plug -1-.
• ‒ Unclip the accelerator cable -2- out of the air cleaner upper part.
• ‒ Pull crankcase breather hose -3- off air cleaner upper part.
• ‒ Loosen air cleaner at securing screws marked by arrows.
• ‒ Remove air cleaner.

Installing

• ‒ Installing the air cleaner is carried out in the reverse order.

Note:

Self-tapping screws/bolts are used to secure the air cleaner to plastic intake pipe as well as to secure the air cleaner upper part to the air cleaner lower part. When these screws/bolts are loosed or tightened using a power tool the threads in the intake manifold or the air cleaner lower part may be damaged.

For this reason the use of a power tool can only be used when:

• ◆ The power tool maximum speed is 200 rpm.
• ◆ The tightening torque is set to a maximum of 3 Nm.