Volkswagen Workshop Service and Repair Manuals

Removing and installing regulating flap control unit -J808- and throttle valve module -J338-   Note To remove throttle valve module -J338-, regulating flap control unit -J808- must first be removed. Special tools and workshop equipment required

t  Torque wrench (4…20 Nm) -V.A.G 1410-

t  Hose clip pliers -VAS 6340- Removing regulating flap control unit -J808- Engine cover ► November 2006

–  Release vacuum hose from vacuum reservoir -arrow- and pull off. –  Lift engine cover panel at points -1- and pull it forwards in direction of -arrow-. Engine cover November 2006 ►

–  Pull vacuum hose off -arrow-. –  Lift engine cover panel at points -1- and pull it forwards in direction of -arrow-. –  Remove securing bolts -1-.

–  Detach spring-type clips and pull off hose -2- on activated charcoal filter system solenoid valve 1 -N80- and pressure pipe -3-. –  Unscrew securing bolt for pressure pipe -3- on turbocharger and pull pressure pipe -3- off.

–  Pull off all connectors and hose connections on intake connecting pipe -4- and regulating flap control unit -J808-.

–  Unscrew intake connecting pipe securing bolts -arrows- and pull intake connecting pipe upwards with regulating flap control unit -J808-.

–  Unscrew securing bolts -arrows-. Removing throttle valve module -J338- –  Detach coolant hose -1- from hose clips.

–  Pull connector -2- off intake air temperature sender 3 -G520- with intake manifold pressure sender 3 -G583-. –  Remove charge air hose -3- from throttle valve module -J338- and charge air pipe.

–  Unscrew securing bolts -arrows- and pull throttle valve module -J338- from intake manifold connection. Installing Installation is carried out in the reverse order. When installing, note the following: t  Always renew gaskets and seals. t  Hose connections and hoses for charge air system must be free of oil and grease before assembly. t  Secure all hose connections with hose clips which conform to production standard. Engine cover ► November 2006

–  Place vacuum hose -2- onto vacuum reservoir union -1-.   Note Ensure that the vacuum hose is locked onto the union -2-.

–  Push engine cover panel down at points -1- in direction of -arrow- until it engages. Engine cover November 2006 ►

–  Push engine cover panel down at points -1- in direction of -arrow- until it engages. –  Fit vacuum hose onto connection -arrow-. Specified torques: Assembly overview - part I, intake manifold → Chapter. If a new regulating flap control unit or throttle valve module has been installed: –  Erase learnt values and adapt engine control unit -J623- to regulating flap control unit and throttle valve module → Vehicle diagnostic tester„Guided functions“.