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Table of Contents > Mixture preparation - injection > Injection system > Removing and installing intake manifold with fuel rail

VW Passat B6 Service Manual ➜ Removing and installing intake manifold with fuel rail

CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...  
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018  
10 - Air flow control flaps  
11 - Seal  
❑ Renew  
12 - Intake manifold  
❑ Removing and installing ⇒ page 473  
13 - Vacuum unit for air flow control flaps  
❑ Checking ⇒ page 496  
14 - Throttle valve module - J338- , throttle valve drive for electric throttle operation - G186-  
❑ Throttle valve drive angle sender 1 for electric throttle - G187- and throttle valve drive angle sender 2 for  
electric throttle - G188-  
❑ After renewing throttle valve module - J338- it must be reprogrammed to engine control unit - J623-  
⇒ Vehicle diagnostic tester via “Guided Functions”  
15 - Bolts for intake manifold  
❑ Pre-tighten to 3 Nm and tighten to 9 Nm  
16 - Intake manifold flap potentiometer - G336-  
❑ To remove and install, remove intake manifold ⇒ page 473 .  
17 - Fuel pressure sender - G247-  
❑ 27 Nm  
❑ Lubricate thread with clean engine oil  
❑ Checking ⇒ page 493  
❑ Removing and installing ⇒ page 486  
Other specified torques  
Further specified torques can be found at end of chapter entitled  
“Disconnecting fuel rail from intake manifold” ⇒ page 480 .  
2.9  
Removing and installing intake manifold  
with fuel rail  
If intake manifold is renewed, intake manifold flap potentiometer  
- G336- must be adapted to engine control unit - J623- using a  
vehicle diagnostic tester .  
2. Injection system  
473  
 
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...  
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018  
Special tools and workshop  
equipment required  
♦ Bit - T10347-  
♦ Oil filter tool - 3417-  
♦ Torque wrench - V.A.G 1331-  
Note  
Observe all relevant safety precautions ⇒ page 278 .  
Observe rules for cleanliness ⇒ page 280 .  
The injectors can only be accessed after removal of the intake  
manifold and fuel rail with air flow control flap.  
Combustion chamber ring seal (Teflon) and O-ring must al‐  
ways be renewed.  
Assembly overview - intake manifold ⇒ page 469 .  
Assembly overview - fuel rail ⇒ page 472  
474  
Rep. gr.24 - Mixture preparation - injection  
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...  
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018  
Removing  
– Only vehicles with sound generator: Remove charge air duct  
to sound generator ⇒ page 455 .  
– Remove engine cover panel ⇒ page 141 .  
– Clean joint between intake manifold and cylinder head.  
– Remove air filter housing ⇒ page 467 .  
Golf, Eos, Scirocco:  
– Remove radiator cowl ⇒ page 273 .  
All:  
– Disconnect vacuum line -arrow- to activated charcoal filter.  
– Disconnect the following electrical connectors:  
♦ Intake air temperature sender - G42- -1-  
♦ Throttle valve module - J338- -2-  
♦ Activated charcoal filter solenoid valve 1 - N80-  
♦ Hall sender - G40-  
– Disconnect vacuum line -1- at connecting point -2- and remove  
the crankcase breather hose -3-.  
– Unscrew bolts -arrows- for fuel supply pipe and lay pipe to  
side.  
2. Injection system  
475  
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...  
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018  
WARNING  
The fuel system is pressurised.  
Danger of injury caused by fuel spray.  
♦ Wear protective goggles.  
♦ Wear protective gloves.  
♦ To release pressure, wrap a clean cloth around the con‐  
nection and carefully loosen the connection.  
– Unscrew fuel pipe union nut -lower arrow-.  
– Pull vacuum pipe -arrow- from intake manifold flap valve -  
N316- .  
– Unscrew coolant line bolts -arrows- from intake manifold.  
– Pull electrical connector -1- from fuel pressure sender -  
G247- .  
476  
Rep. gr.24 - Mixture preparation - injection