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4.3 Intake Manifold, Removing and Installing
Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015
4 Intake Manifold
⇒ “4.1 Overview - Intake Manifold”, page 296 . ⇒ “4.2 Overview - Intake Manifold Lower Section with Fuel Rail”, Protected by copyright . Copying for pivate or commerci al pur po s e s , i n p a r t r o r in w ho le, is not permitted unless authorised by Volkswagen AG. Volkswagen AG does notguarantee or accept any liabilit y wi th res pect t o t h e c o r r e c t n e ss o f in format ion in this document. Copyright by Volkswagen AG. page 300 ⇒ “4.3 Intake Manifold, Removing and Installing”, page 304 . ⇒ “4.4 Fuel Rail, Removing and Installing, Direct Fuel Injection”, page 309 . ⇒ “4.5 Throttle Valve Control Module GX3 , Removing and In‐stalling”, page 309 . ⇒ “4.6 Throttle Valve Control Module, Cleaning”, page 311 . 4.1 Overview - Intake Manifold ⇒ “4.1.1 Overview - Intake Manifold, without Intake-Manifold Fuel Injection”, page 296 . 4.1.1 Overview - Intake Manifold, without Intake-Manifold Fuel Injection 1 - Intake Manifold ❑ Removing and instal‐ling. Refer to ⇒ “4.3 Intake Manifold, Removing and Instal‐ling”, page 304 . 2 - Intake Manifold Runner Po‐sition Sensor - G336❑ The Intake Manifold Runner Position Sensor - G336- needs to be adapted to the Engine Control Module - J623each time the sensor is removed and installed or replaced. See “Gui‐ded Functions”; to do so, use a Vehicle Diag‐nostic Tester .
3 - Bolt ❑ 5 Nm ❑ Intake Air Temperature
Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015
Sensor - G42-
4 - Intake Air Temperature Sensor - G42- with Manifold Absolute Pressure Sensor - G71❑ 5 Nm
5 - O-Ring ❑ Replace after removing 6 - Intake Manifold Bolt ❑ 9 Nm
Protected by copyright . Copying fo pivate or commerci al pur po s e s , i
7 - Outer Intake Manifold Threaded Pin ❑ 9 Nm ❑ Installed on the outer positions as a guide 8 - Seal ❑ Check and replace if damaged p a r t o r in w ho le, is not permitted unless authorised by Volkswagen AG. Volkswagen AG does notguarantee or accept any liabilit y wi th res pect t o t h e c o r r e c t n e ss o f n 9 - Channel Separating Plate Vacuum Diaphragm (Intake Manifold Flaps) 10 - Fuel Injector Fuel Rail 11 - Fuel Injectors ❑ Replace the O-ring and Teflon® ring ❑ Note correct installation position ❑ Removing and installing. Refer to ⇒ “2.2 Fuel Injectors, Removing and Installing”, page 285 . 12 - Bolt ❑ 9 Nm ❑ High pressure line to intake manifold 13 - Bracket ❑ Connectors 14 - Bolt ❑ 5 Nm r 15 - Bolt ❑ 20 Nm ❑ For the intake manifold bracket r 16 - Throttle Valve Control Module - J338- Bolts ❑ 7 Nm 17 - Nut For The Intake Manifold Support ❑ 10 Nm 18 - Intake Manifold Support 19 - Rubber Bushing in format ion in this document. Copyright by Volkswagen AG. ❑ 5 Nm
20 - Throttle Valve Control Module - J338- , EPC Throttle Drive - G186- , ❑ EPC Throttle Drive Angle Sensor 1 - G187- and EPC Throttle Drive Angle Sensor 2 - G188❑ The Throttle Valve Control Module - J338- must be adapted to the Engine Control Module - J623- when it is removed and installed or replaced. See “Guided Functions”; to do so, use Vehicle Diagnostic Tester 21 - Seal ❑ Replace after removing 22 - Fuel Pressure Sensor - G247❑ ⇒ “5.2 Fuel Pressure Sensor G247 , Removing and Installing”, page 314 . ❑ Coat the sealing point and thread with clean engine oil. 23 - Bolts ❑ 9 Nm
Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015
❑ Fuel rail to cylinder head
1 - Intake Manifold ❑ Removing and instal‐ling. Refer to ⇒ “4.3 Intake Manifold, Removing and Instal‐ling”, page 304 . 2 - Intake Manifold Bolt ❑ 9 Nm
3 - Intake Manifold Runner Control Valve - N316-
4 - Channel Separating Plate Vacuum Diaphragm (Intake Manifold Flaps) 5 - High Pressure Pump Bolts ❑ 20 Nm ❑ Replace after removing ❑ Tighten uniformly 6 - Connector ❑ For the Fuel Pressure Regulator Valve - N2767 - Fuel Pressure Regulator Valve - N276-
Protected by copyright . Copying fo pivate or commerci al pur po s e s , i n p a r t r o r in w ho le, is not permitted unless authorised by Volkswagen AG. Volkswagen AG does notguarantee or accept any liabilit y wi th res pect t o t h e c o r r e c t n e ss o f in format ion in this document. Copyright by Volkswagen AG. r 8 - High Pressure Pump ❑ With Fuel Pressure Regulator Valve - N276❑ There is an electric fuel pump located in the fuel tank that supplies the fuel to the mechanical high pressure pump. ❑ When installing, make sure that no dirt enters the fuel system. ❑ Must not be subjected to knocks and impacts ❑ The fuel system must be without pressure to install the high-pressure pump, releasing fuel pressure. Refer to ⇒ “1.2 High Fuel Pressure, Reducing”, page 283 . ❑ Install the fuel lines free of tension ❑ Removing and installing. Refer to ⇒ “7.2 High Pressure Pump, Removing and Installing”, page 328 . 9 - Roller Tappet ❑ May remain in the vacuum pump after removing the high pressure pump, removable 10 - High Pressure Line ❑ To the combustion chamber fuel injectors fuel rail ❑ Lubricate the high pressure line with engine oil ❑ Do not install a tensioned high pressure line (pay attention to cleanliness). 11 - Fuel Line ❑ To the fuel rail intake manifold fuel injectors
Protected by copyright . Copying fo pivate or commerci al pur po s e s , i n p a r t r o r in w ho le, is not permitted unless authorised by Volkswagen AG. Volkswagen AG does notguarantee or accept any liabilit y wi th res pect t o t h e c o r r e c t n e ss o f in format ion in this document. Copyright by Volkswagen AG. r 12 - High Pressure Line Union Nut ❑ 27 Nm ❑ Lubricate the high pressure line with engine oil 13 - High Pressure Line Connection ❑ 40 Nm ❑ Replace after removing ❑ Coat the threads with clean engine oil. 14 - Fuel Injectors ❑ Replace the O-ring and Teflon® ring ❑ Note correct installation position ❑ Removing and installing. Refer to ⇒ “2.2 Fuel Injectors, Removing and Installing”, page 15 - Combustion Chamber Fuel Injector Fuel Rail 16 - Fuel Pressure Sensor - G247❑ 27 Nm ❑ Coat the sealing point with clean engine oil. ❑ Removing and installing. Refer to ⇒ “5.2 Fuel Pressure Sensor G247 , Removing and Installing”, page 314 . 17 - Seal ❑ Replace after removing 18 - Throttle Valve Control Module - GX3❑ Consists of: EPC Throttle Drive - G186285 . EPC Throttle Drive Angle Sensor 1 - G187EPCThrottle Drive Angle Sensor 2 - G188❑ After replacing or removing and installing the Throttle Valve Control Module - GX3- must be adapted to the Engine Control Module - J623- . Refer to Vehicle Diagnostic Tester 19 - Throttle Valve Control Module - GX3- Bolts ❑ 7 Nm 20 - Intake Manifold Support 21 - Bolt ❑ 20 Nm ❑ For the intake manifold bracket 22 - Intake Manifold Support Nut ❑ 10 Nm 23 - Rubber Bushing ❑ 5 Nm Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015
Protected by copyright . Copying fo pivate or commerci al pur po s e s , i n p a r t r o r in w ho le, is not permitted unless authorised by Volkswagen AG. Volkswagen AG does notguarantee or accept any liabilit y wi th res pect t o t h e c o r r e c t n e ss o f in format ion in this document. Copyright by Volkswagen AG. 4.2 Overview - Intake Manifold Lower Sec‐tion with Fuel Rail ⇒ “4.2.1 Overview - Intake Manifold Lower Section with Fuel Rail, Direct Fuel Injection”, page 300 4.2.1 Overview - Intake Manifold Lower Section with Fuel Rail, Direct Fuel Injec‐tion r 1 - Fuel Injector ❑ With combustion cham‐ber seal (Teflon® seal), always replace ❑ Replace the O-rings. ❑ Make sure it is installed in the correct position. ❑ Removing and instal‐ling. Refer to ⇒ “2.2 Fuel Injectors, Removing and Instal‐ling”, page 285 . 2 - Support Ring ❑ Replace after removing Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 3 - Fuel Rail for Combustion Chamber Fuel Injector ❑ 9 Nm ❑ Removing and instal‐ling. Refer to ⇒ “4.4 Fuel Rail, Re‐moving and Installing, Direct Fuel Injection”, page 309 . 4 - Roller Tappet 5 - Fuel Pressure Regulator Valve - N276-
6 - High Pressure Pump ❑ With Fuel Pressure Regulator Valve - N276❑ There is an electric fuel pump located in the fuel tank that supplies the fuel to the mechanical high pressure pump. ❑ Pay attention when installing the high pressure pump, that no dirt enters the fuel system. ❑ The fuel system must be without pressure to install the high-pressure pump, releasing fuel pressure. Refer to ⇒ “1.2 High Fuel Pressure, Reducing”, page 283 . ❑ Install the fuel lines free of tension ❑ Removing and installing. Refer to ⇒ “7.2 High Pressure Pump, Removing and Installing”, page 328 . 7 - High Pressure Pump Bolts ❑ 20 Nm ❑ Replace after removing ❑ Tighten uniformly 8 - High Pressure Line Connection On High Pressure Pump 9 - High Pressure Line Union Nut ❑ 27 Nm
