1.4 TSI engine (EA111) · Mixture preparation – injection · Intake manifold

Removing and installing regulating flap control unit - J808- and throttle valve module - J338-

Special tools and workshop equipment required

  • Torque wrench - V.A.G 1410-
  • Hose clamp pliers - VAS 6340-

Removing regulating flap control unit - J808-

  • Lift engine cover panel at points -1- and pull it forwards in direction of -arrow-.
  • Remove securing bolts -1-.
  • Pull off all connectors and hose connections on intake connecting pipe -4- and regulating flap control unit - J808-.
  • Detach spring-type clips and pull off hose -2- on activated charcoal filter system solenoid valve 1 - N80- and pressure pipe -3-.
  • Unscrew securing bolt for pressure pipe -3- on turbocharger and pull pressure pipe -3- off.
  • Unscrew intake connecting pipe securing bolts -arrows- and pull intake connecting pipe upwards with regulating flap control unit - J808-.
  • Unscrew securing bolts -arrows-.

Removing throttle valve module - J338-

  • Detach coolant hose -1- from hose clips.
  • Pull connector -2- off intake air temperature sender 3 - G520- with intake manifold pressure sender 3 - G583-.
  • Remove charge air hose -3- from throttle valve module - J338- and charge air pipe.
  • Unscrew securing bolts -arrows- and pull throttle valve module - J338- from intake manifold connection.

Installing

Installation is carried out in the reverse order. When installing, note the following:

  • Seals and O-rings must be renewed and coated lightly with clean engine oil before installing.
  • Hose connections and hoses for charge air system must be free of oil and grease before assembly.
  • Secure all hose connections with hose clips which conform to production standard.
  • Push engine cover panel down at points -1- in direction of -arrow- until it engages.

Specified torques:

Assembly overview - intake manifold ⇒ 2.1 Assembly overview - intake manifold.

If a new regulating flap control unit or throttle valve module has been installed:

  • Erase learnt values and adapt engine control unit - J623- to regulating flap control unit and throttle valve module ⇒ Vehicle diagnostic tester “Guided functions”.