Volkswagen Cars 2000-05

Throttle Body

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Removal & Installation



  1. Detach the negative battery cable.
  2.  
  3. Disconnect the air intake duct and place it off to the side of the throttle valve housing.
  4.  
  5. Remove the throttle position sensor wiring harness.
  6.  
  7. Detach the accelerator cable from the housing of the throttle valve.
  8.  
  9. On the VR-6 engine, remove the expansion tank filler cap. Clamp off any coolant hoses that connect to the throttle body and then remove them.
  10.  
  11. On four (4) cylinder models, detach the Evaporative Emissions (EVAP) vent hose from its port on the throttle body.
  12.  
  13. Remove all attaching bolts that hold the throttle body to the intake manifold.
  14.  
  15. Remove the throttle body.
  16.  

To install:

  1. Use a new gasket any time the throttle body has been removed from the intake manifold. If this gasket were to leak, an unmetered air source would enter the engine thus creating a lean condition in the cylinders.
  2.  
  3. If you are replacing the throttle body housing, remember to transfer all sensors to the new unit before installing it back on the intake manifold.
  4.  
  5. The remainder of the installation procedure is the reverse of removal.
  6.  

The throttle body is mounted on the intake manifold inlet downstream of the mixture control unit. The function of the throttle valve is to regulate airflow into the engine. The throttle valve is control by the throttle cable. The throttle valve does not control engine idle speed; that is accomplished by the idle stabilizer valve.



Click image to see an enlarged view

Fig. Exploded view of the throttle body

For component location identification and assistance with removal of this component, refer to the following appropriate exploded view illustration.

  1. Upper intake manifold
  2.  


    First tighten to the lower intake manifold and then to both rear supports
     

  3. Cable duct
  4.  
  5. Torque to 7 ft. lbs. (10 Nm)
  6.  
  7. Support
  8.  


    Located between intake manifold upper section and cylinder head
     

  9. Torque to 18 ft. lbs. (25 Nm)
  10.  
  11. Vacuum line
  12.  
  13. Breather hose
  14.  


    Hose from EVAP canister purge regulator valve
     

  15. Junction piece
  16.  
  17. Throttle valve control module
  18.  


    If replaced, initiate 'Basic Setting' function; requires scan tool. Follow designated procedures.
     

  19. 8-pin connector for throttle valve control module
  20.  
  21. Gasket (always replace)
  22.  
  23. Accelerator pedal support bracket
  24.  
  25. Ground (GND) wires
  26.  
  27. Left rear support
  28.  


    Between upper intake manifold and cylinder head
     
    With engine ground connection
     


 
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