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Removing and installing regulating flap control unitJ808 and throttle valve moduleJ338 > < Intake manifold

Golf Mk6

Assembly overview - intake manifold
   
Assembly overview - intake manifold

Part I
  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.
   
1 - Intake air temperature sender 3 -G520- with intake manifold pressure sender 3 -G583-
2 - 5 Nm
3 - 7 Nm
q   Self-tapping bolt.
q   The securing bolt may only be tightened using a power-operated screwdriver if the screwdriver speed is max. 500 rpm and a max. tightening torque of 7 Nm is set.
4 - Intake connecting pipe
5 - Seal
q   Renew.
q   Before installing, lightly coat seal with clean engine oil.
6 - Regulating flap control unit -J808-
q   Removing and installing → Chapter
  Note
Regulating flap control units with plastic housing need not be adapted to the engine control unit -J623-.
q   If renewed, erase learnt values and adapt engine control unit -J623- → Vehicle diagnostic tester„Guided functions“.
7 - 7 Nm
q   Self-tapping bolt.
q   The securing bolt may only be tightened using a power-operated screwdriver if the screwdriver speed is max. 500 rpm and a max. tightening torque of 7 Nm is set.
8 - Intake connecting pipe
9 - Intake manifold connection
10 - 7 Nm
q   Self-tapping bolt.
q   The securing bolt may only be tightened using a power-operated screwdriver if the screwdriver speed is max. 500 rpm and a max. tightening torque of 7 Nm is set.
11 - 5 Nm
12 - Intake manifold pressure sender -G71-
13 - O-ring
q   Renew.
14 - Intake manifold
  Note
t  If the intake manifold was removed, you must check that all hoses are securely connected on the intake manifold after installation.
t  Pull hoses with fastener to make sure they are securely connected.
q   To remove: removing and installing regulating flap control unit -J808- and throttle valve module -J338- → Chapter.
15 - 20 Nm
16 - Fuel pressure sender -G247-, 22 Nm
q   Checking fuel pressure in high-pressure section → Chapter.
17 - 80 Nm
18 - Intake manifold lower part
q   To remove and install: using "bracket for bits 5/16""" -V.A.G 1766/2- and Bit -3320/2- → Fig.
q   To remove, removing and installing regulating flap control unit -J808-, throttle valve module -J338- and intake manifold → Chapter.
19 - Seal
q   Renew.
q   Note installation position.
20 - 20 Nm
21 - Throttle valve module -J338-
q   Removing and installing → Chapter
q   Clean → Chapter.
q   If renewed, erase learnt values and adapt engine control unit -J623- → Vehicle diagnostic tester„Guided functions“.
22 - 7 Nm
23 - Pressure pipe
q   From turbocharger
24 - Retaining clip
25 - 7 Nm

   
Removing and installing lower part of intake manifold
To remove and install the securing bolt -arrow- use Holder for 5/16 inch bits -V.A.G 1766/2- and Bit -3320/2-.
Part II
  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.
  N24-10685
1 - Connection
q   For fuel supply.
2 - Fuel hose
q   For fuel supply.
q   Low-pressure.
q   To high-pressure pump.
3 - Retaining clamp
4 - Connecting hose
q   To activated charcoal filter solenoid valve 1 -N80-
5 - Activated charcoal filter solenoid valve 1 -N80-
6 - Connecting hose
7 - To pressure pipe.
8 - Connecting pipe
9 - Connecting hose
q   To intake manifold connection.
10 - 8 Nm
11 - Fuel pipe
q   High-pressure.
q   Specified torque for union nuts: 18 Nm.
12 - Connection
q   To intake connecting pipe.
13 - Connecting hose
14 - Non-return valve
q   For crankcase ventilation.
q   Specified torque: 10 Nm
15 - Connecting hose
16 - Charge pressure control solenoid valve -N75-
17 - Connecting hose
18 - Connecting hose
q   To turbocharger.
19 - Connection
20 - 5 Nm
21 - Connecting hose
q   To turbocharger.
22 - Connection
23 - Connection
q   For crankcase ventilation.
24 - Connecting hose
q   For crankcase ventilation.
25 - Connecting hose
q   To charge pressure control solenoid valve -N75-.
26 - Connection
q   For crankcase ventilation.
q   Connected to valve timing housing.
q   Specified torque: 10 Nm

   

Removing and installing regulating flap control unitJ808 and throttle valve moduleJ338 > < Intake manifold