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

Removing and installing
regulating flap control unit
J808
and
throttle valve module
J338
Note
To remove
throttle valve module
J338
,
regulating flap control unit
J808
must first be removed.
Special tools and workshop equipment required
Torque wrench (4…20 Nm)
V.A.G 1410
Hose clip pliers
VAS 6340
Removing
regulating flap control unit
J808
Engine cover ► November 2006
Release vacuum hose from vacuum reservoir
arrow
and pull off.
Lift engine cover panel at points
1
and pull it forwards in direction of
arrow
.
Engine cover November 2006 ►
Pull vacuum hose off
arrow
.
Lift engine cover panel at points
1
and pull it forwards in direction of
arrow
.
Remove securing bolts
1
.
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.
Pull off all connectors and hose connections on intake connecting pipe
4
and
regulating flap control unit
J808
.
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:
Always renew gaskets and seals.
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.
Engine cover ► November 2006
Place vacuum hose
2
onto vacuum reservoir union
1
.
Note
Ensure that the vacuum hose is locked onto the union
2
.
Push engine cover panel down at points
1
in direction of
arrow
until it engages.
Engine cover November 2006 ►
Push engine cover panel down at points
1
in direction of
arrow
until it engages.
Fit vacuum hose onto connection
arrow
.
Specified torques:
Assembly overview - part I, intake manifold
Chapter
.
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”
.