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Removing and installing intake manifold > < Intake manifold

Polo Mk5

Assembly overview - intake manifold
Assembly overview - intake manifold
  Note
t  If hoses have been removed during repair, you must check that all hoses are firmly connected after installation.
t  Pull hoses with fastener to make sure they are securely connected.
   

  Note
t  If hoses have been removed during repair, you must check that all hoses are firmly connected after installation.
t  Pull hoses with fastener to make sure they are securely connected.
Part I
   
1 - Connecting hose
q   To air filter.
2 - Connector
q   For intake manifold sender -G71-.
  Note
t  Suction pipe pressure transducer -G71- is clipped to suction pipe.
t  If a clip is damaged, use securing bolts → ETKA (electronic parts catalogue).
t  Specified torque: 5 Nm
3 - Connector
4 - 10 Nm
5 - Non-return valve
q   For crankcase ventilation.
6 - Connecting hose
q   To turbocharger.
7 - O-rings
q   Renew.
8 - Intake manifold
q   Remove and install → Chapter
9 - Connecting hose
  Note
Installed in engines with switchable coolant pump only.
q   To coolant pump.
10 - Coolant circuit solenoid valve -N492-
  Note
Installed in engines with switchable coolant pump only.
11 - Connection
q   For fuel supply.
12 - Spring-type clip
q   Removing and installing with hose clip pliers -VAS 6340-.
13 - Fuel hose
q   Low-pressure.
q   To high-pressure pump.
14 - Activated charcoal filter solenoid valve 1 -N80-
15 - Connecting hose
q   To activated charcoal filter.
16 - Connecting hoses
17 - Connector
q   For throttle valve module -J338-.
18 - Connecting hose
19 - Connector
q   For charge air pressure sender -G31- with intake air temperature sender 2 -G299-.

Part II
   
1 - Pressure pipe
2 - 7 Nm
3 - Retaining clip
4 - Fuel pressure sender -G247-, 22 Nm
q   Checking fuel pressure sender -G247- → Chapter.
5 - Fuel rail
6 - 20 Nm
7 - 30 Nm
8 - 25 Nm
9 - 25 Nm
10 - O-ring
q   Renew.
11 - Spring element
q   Observe proper seating of injector.
12 - Injector, cylinder 1 -N30-
q   Injector, cylinder 2 -N31-
q   Injector, cylinder 3 -N32-
q   Injector, cylinder 4 -N33-
q   With Teflon seal and support washer.
q   After removing injector, Teflon seal and support washer must be renewed → Chapter.
q   Removing and installing injectors → Chapter.
13 - Cylinder head
q   Remove and install → Chapter
14 - 20 Nm
15 - Intake manifold
q   With intake manifold pressure sender -G71- (clipped onto intake manifold)
q   Remove and install → Chapter
16 - Seal
q   Renew.
17 - Throttle valve module -J338-
q   Remove and install → Chapter
q   Clean → Chapter.
q   If renewed, erase learnt values and adapt engine control unit -J623- → Vehicle diagnostic tester„Guided functions“.
18 - Adapter
19 - O-ring
q   Renew.
20 - 7 Nm
21 - O-ring
q   Renew.
22 - Charge air pressure sender -G31- with intake air temperature sender 2 -G299-
23 - 5 Nm

   

Removing and installing intake manifold > < Intake manifold