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Intake manifold - remove and install > < Component location

Polo Mk4

Injection components - remove and install
Injection components - remove and install
BAH/BPA engines
   
1 - 80 pole connector
q   For Engine control unit -J623-.
q   Connect or disconnect the connector only with ignition switched off.
q   Unlock to remove.
2 - Engine control unit -J623-
q   For the injection system, lambda control, Magnetic valve I for activated charcoal reservoir -N80-, knock adjustment, speed limitation, ignition and self-diagnosis.
q   When replacing the Engine control unit -J623-, carry out adaptation → Chapter.
3 - Support
q   From the Engine control unit -J623-.
4 - 3 Nm
5 - Connector
q   Black, 4 poles.
q   From the Intake manifold pressure sensor -G71- with the intake air temperature sensor -G42-.
q   Gold plated connector contacts.
6 - Connector
q   Black, 3 poles.
q   From Engine speed sensor -G28-.
7 - Air filter set
q   Remove and install the air filter set → Chapter.
q   Disassemble and assemble → Chapter.
8 - Fastening clip
q   Observe model.
9 - Cable guide
q   Fastened to the fuel rail.
10 - Connector
q   Black, 2 poles.
q   From the Cylinder 1 injector -N30-,Cylinder 2 injector -N31-, Cylinder 3 injector -N32- and Cylinder 4 injector -N33-.
11 - Supply line
q   Black with white mark.
q   Fasten with spring braces.
q   Make sure it is well fastened.
q   From the fuel filter.
12 - 10 Nm
13 - Fuel rail with injectors
q   Remove and install → Chapter.
14 - 20 Nm
15 - Connector
q   Black, 6 poles.
q   For Throttle valve module -J338-.
q   Gold plated connector contacts.
16 - From the Magnetic valve I for activated charcoal filter -N80-
q   Fasten with spring braces.
17 - For brake servo
18 - Intake manifold
q   Remove and install → Chapter.
19 - Sealing ring
q   Replace.
q   Check installation position.
20 - Lambda probe -G39-, 50 Nm
q   Installation location: In the forward exhaust pipe.
q   Lubricate only the thread with High-temperature paste -G 052 112 A3-; do not reach probe body grooves.
q   Remove and install with the Set of sockets for Lambda probe -3337- for Lambda probe -G39-.
q   Power is supplied to heat the Lambda probe -G39- through the Fuel pump relay -J17-.
21 - Connector
q   Black, 4 poles.
q   For the Lambda probe -G39- before the catalytic converter and Lambda probe heating -Z19-.
q   Contacts 3 and 4 gold plated.
22 - Engine speed sensor -G28-
q   Installation location: On cylinder block, intake side.
23 - 5 Nm
24 - Guide tube
q   To the oil dipstick.
25 - 3 Nm
26 - Clip
q   Make sure it is well fastened.
27 - Washer
q   Replace.
28 - Connector
q   Black, 2 poles.
q   From Coolant temperature sensor -G62-.
q   Gold plated connector contacts.
29 - Plug
q   If necessary, depressurize the system before removal.
30 - Coolant temperature sensor -G62-
q   For Engine control unit -J623-.
q   If necessary, depressurize the system before removal.
31 - Thermostat housing

CCRA engine
Lambda probe -G39- in exhaust system manifuld.
   
1 - Connector
q   For Engine control unit -J623-.
q   Connect or disconnect the connector only with ignition switched off.
q   Unlock to disengage.
2 - Engine control unit -J623-
q   For the injection system, lambda control, magnetic valve I for the activated charcoal filter, knock adjustment, speed limitation, ignition and self-diagnosis.
q   When replacing the Engine control unit -J623-, adjust to Immobilizer control unit -J362- → Chapter.
3 - Connector
q   Black, 4 poles.
q   From the Intake manifold pressure sensor -G71- with the intake air temperature sensor -G42-.
q   Gold plated connector contacts.
4 - Connector
q   Black, 3 poles.
q   From Engine speed sensor -G28-.
5 - Air filter set
q   Disassemble and assemble → Chapter.
6 - Fastening clip
q   Observe model.
7 - Cable guide
q   Fastened to the fuel rail.
8 - Connector
q   Black, 2 poles.
q   From the Cylinder 1 injector -N30-,Cylinder 2 injector -N31-, Cylinder 3 injector -N32- and Cylinder 4 injector -N33-.
9 - Fuel supply lines
q   Black with white mark.
q   Fasten with spring braces.
q   Make sure it is well fastened.
q   From the fuel filter.
10 - 10 Nm
11 - Fuel rail with injectors
q   With Resistance for fuel pre-heating -Z66-, Resistance 2 for fuel pre-heating -Z108-, Resistance 3 for fuel pre-heating -Z109- and Resistance 4 for fuel pre-heating -Z110- only for vehicles equipped with E-Flex cold start system.
q   Remove and install → Chapter.
12 - 20 Nm
13 - Connector
q   Black, 6 poles.
q   For Throttle valve module -J338-.
q   Gold plated connector contacts.
14 - For Magnetic valve I for the activated charcoal filter -N80-
q   Fasten with spring braces.
15 - For brake servo
16 - Intake manifold
q   Remove and install → Chapter.
17 - Sealing ring
q   Replace.
q   Check installation position.
18 - Lambda probe behind catalytic converter -G130-, 50  Nm
q   Installation location: On the exhaust tube, front part, in 10/2010 with the OBD BR2.
q   Lubricate only the thread with High-temperature paste -G 052 112 A3-; ensure that the High-temperature paste -G 052 112 A3- does not reach the grooves on the body of Lambda probe after catalyst -G130-.
q   Remove and install with the Set of sockets for Lambda probe -3337-.
q   Power is supplied to heat the Lambda probe -G39- through the Fuel pump relay -J17-.
19 - Connector
q   Black, 4 poles.
q   To Lambda probe after the catalytic converter -G130- .
q   Contacts 3 and 4 gold plated.
20 - Engine speed sensor -G28-
q   Installation location: On cylinder block, intake side.
21 - 5 Nm
22 - Guide tube
q   To the oil dipstick.
23 - 3 Nm
24 - Clip
q   Make sure it is well fastened.
25 - Sealing ring
q   Replace.
26 - Connector
q   Black, 4 poles.
q   From Coolant temperature sensor -G62-.
q   Gold plated connector contacts.
27 - Plug
q   If necessary, depressurize the system before removal.
28 - Coolant temperature sensor -G62-
q   From the Engine control unit -J623-.
q   If necessary, depressurize the system before removal.
29 - Thermostat housing

   

Intake manifold - remove and install > < Component location