Volkswagen Golf / Golf GTI / Golf Variant. Manual - part 715

4

Intake Manifold

⇒ “4.1 Overview - Intake Manifold”, page 296

 .

⇒ “4.2 Overview - Intake Manifold Lower Section with Fuel Rail”,

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 - J623-

each 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

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

7 - Outer Intake Manifold Threaded Pin

❑ 9 Nm
❑ Installed on the outer positions as a guide

8 - Seal

❑ Check and replace if damaged

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

15 - Bolt

❑ 20 Nm
❑ For the intake manifold bracket

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

❑ 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

❑ Fuel rail to cylinder head

4.1.2

Overview - Intake Manifold, with 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 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 - N276-

7 - Fuel Pressure Regulator

Valve - N276-
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

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 285

 .

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 - G186-

EPC Throttle Drive Angle Sensor 1 - G187-

EPCThrottle 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