Section B - 2.8 Liter 5 Valve V6
SECTION B - 2.8 LITER 5 VALVE V6
Kit 078 198 998 M
Kit 078 198 998 N
Kit 078 198 998 P
Type of kit will be determined after viewing the throttle valve control module.
- Open hood
- Turn screws -1- and remove engine cover
- Remove intake air hose between Mass Air Flow (MAF) sensor and air intake elbow by loosening clamps -2-.
- Remove three bolts -3- securing solenoid plate assembly located rearward of the intake manifold.
- Disconnect vacuum hoses and electrical connectors (note location of vacuum hoses) as necessary.
- Unclip wiring support -3-
- Disconnect connector-1- for intake air temperature sensor.
- Move disconnected solenoid plate assembly to one side
- Disconnect connector -2- from throttle valve control module
- Remove cruise control vacuum unit from support -4-
- Remove cap screw -C- on air intake elbow and slide elbow rearward
- Disconnect crankcase ventilation hose -B- from intake air elbow and remove elbow.
- Disconnect vacuum hose -A- from throttle valve control module to evaporative emission (EVAP) canister purge regulator.
Throttle valve control module removing
Note:
A support (90 mm or 3.5 inches) under the accelerator pedal will ease cable tension and aid in disassembly.
- Remove throttle valve control module from intake manifold by removing screws -1-, -2-, and -3- with a 5 mm hexagon socket and screw -4- with an 8 mm hexagon socket.
Note:
Screws -2- and -3- also secure throttle valve heating tube, and screw -2- also secures ground wire.
- Carefully disconnect throttle cable and cruise control linkage (do not remove accelerator pedal cable retainer from throttle body) and set aside.
- Check throttle valve control module for two vacuum ports -1-
- If two vacuum ports are present (one with rubber cap) use bypass kit 078 198998 P
- If vacuum port with rubber cap is not present, use bypass kit 078 198 998 M for manual transmission vehicles or bypass kit 078 198 998 N for automatic transmission vehicles.
Vacuum booster bypass installing
Prepare the throttle valve control module before installing:
- From the kit install angle hose -1-, check valve -2- and bypass hose -3- on the throttle valve control module, making sure that the marks -A- and -B- on vacuum hoses are aligned as shown.
Important:
The arrow -C-on the check valve must point in the direction of the throttle valve control module.
- From the kit, use 2 pinch clamps to secure angled hose -1- and a screw clamp to secure bypass hose -3-.
- Correct position of hose assembly on throttle valve control module.
- Clean the mounting surface of the intake manifold and make certain 0-ring gasket is in place before installing the throttle valve control module
- Apply paste sealer from the kit on area -1- of the throttle valve heating tube
- When the throttle valve control module is bolted on, ground wire -2- will be secured with the throttle valve heating tube bracket -3-.
- Install throttle valve control module with new hoses and valve and secure with four screws (10 Nm or 7 ft lb).
- Reconnect throttle cable and cruise control linkage
- Place air intake elbow in front of throttle body, reconnect crank case vent hose -B-, slide elbow to correct position on throttle body and secure with cap screw -C- (10 Nm or 7 ft lb).
- Reconnect vacuum hose -A- for evaporative emission (EVAP) canister purge regulator to throttle valve control module with a pinch clamp.
- Remove the rubber elbow between the vacuum amplifier and the brake booster vacuum pipe
- Remove rubber seal and plenum panel cover
- Remove vacuum pipe -1- to brake booster
- Install new vacuum pipe 8D1 611931 AR from brake booster to bypass hose.
- Connect bypass hose -C- to vacuum amplifier -A- and secure using screw clamp.
- Connect bypass hose -C- to vacuum pipe -B- to brake booster and secure using new screw clamp N 10201801
Vacuum ports
1 Port to the EVAP - valve
2 To brake booster
3 To intake manifold
4 Connection for bypass
- Reconnect connector to throttle valve control module
- Reinstall solenoid plate with three screws
- Reconnect previously disconnected vacuum lines
- Reconnect connector for intake air temperature sensor
- Reinstall cruise control vacuum unit and secure (10 Nm or 7 ft lb)
- Reinstall wiring support
- Reinstall intake air hose between mass air flow sensor and air intake elbow, and secure with clamps (10 Nm or 7 ft lb)
- Reinstall plenum panel cover and seal
- Reinstall engine cover
- Remove support from under accelerator pedal
- Use VAG 1551 or VAG 5051 and set throttle adaptation
- Close hood
- Properly dispose of all removed parts