A. Secure Venturi
Work Procedure1990-1992 California
16V GLI/GTI and Passat Vehicles
- Open hood.
A. Secure Venturi
^ Check throttle body version In vehicle.
If throttle body shows the new type vacuum nozzle and modified linkage, neither the securing of the venturi nor the clip installation is necessary.
If vehicle is equipped with any other throttle body with a straight vacuum nozzle and a linkage arm, proceed as as outlined below:
^ Repair
- Remove throttle body from intake manifold.
- Carefully clamp throttle body into vise using jaw protectors and old base gasket to ensure that throttle body is not damaged.
- Using pliers, remove vacuum nozzle and discard. If nozzle does not pull out, break it off at the throttle body.
- With venturi held firmly in proper seat position, drill out vacuum nozzle hole, using drill supplied in kit KL3395. Drill completely through venturi vacuum channel.
- Using 6 mm pre-cutting tap from kit KL3395, cut thread in throttle housing including venturi. Cut final thread using finishing tap from kit.
Caution!
Use thread cutting grease from kit to collect cutting chips.
- De-burr threaded hole in venturi -A-. With compressed air, clean venturi and hole to ensure that all metal chips are removed.
- Using lock washer, screw new nozzle, Part No. 200 133 001 into prepared hole (arrow). Check that nozzle does not protrude into venturi at -A-. Use appropriate 6 mm washer from kit if necessary.
- Remove nozzle again, apply Loctite(R) and screw into hole.
- Tighten nozzle to 7 N-m (60 ... 65 in.lb.) with torque wrench.
Caution!
DO NOT overtighten. DO NOT use click-type torque wrench.
- Make sure that new vacuum nozzle is not obstructed by dirt, grease, etc., that may have been present in tool socket.
Install throttle linkage clip, where applicable
(Manual transmission only)
- Check throttle body linkage for previously installed clip.
- If clip is present, proceed to "Check Closed Throttle Position (CTP) Switch and Wide Open Throttle (WOT) Switch".
- Check gap between throttle body linkage and CTP switch actuation arm (arrow).
- If there is NO gap, clip is not required. Proceed to "Check Closed Throttle Position (CTP) Switch and Wide Open Throttle (WOT) Switch".
- If gap is visible, install linkage clip, Part No. 051 133 806A.
- Slide clip into gap (arrow).
- Tabs on clip must be past CTP switch actuation arm.
- Using needle nose pliers, bend tabs to retain clip.
Passat with automatic transmission only:
- Check Throttle Position Sensor (TPS) terminals for goldplated terminals. For instructions see Step B. Replace TPS if necessary.
- Check adjustment of TPS by first loosening adjustment screws, then turning TPS clockwise until inside connection is felt. Tighten screws.
GLI 16V and GTI 16V only:
- Remove plastic intake air duct between connecting boots and replace with new duct, Part No. 027 133 373P. Reuse clamps. Position clamps with screws on top.
Check Closed Throttle Position (CTP) and Wide Open Throttle (WOT) Switch
- Connect test adaptor VAG 1501 to CTP/WOT switch connector. Harness connector remains disconnected.
- Switch Fluke 83 multimeter to resistance range.
- Connect multimeter to adaptor leads 1 and 2, using jumpers from adaptor kit VW 1594.
^ must be 0 Ohms (continuity)
- Open throttle slightly.
- CTP switch must switch OFF and resistance increase to infinity Ohms (no continuity)
- If NOT OK, replace CTP/WOT switch
Checking and adjusting CTP/WOT switch
- Slowly close throttle while checking switch point (O Ohms) of CTP switch with feeler gauge between throttle lever and idle stop (limiter screw). switch point before idle stop = 0.15 to 0.5 mm (.006 to.020 in.) If NOT OK, adjust gap by loosening and adjusting switch
- Measure resistance between adaptor leads 2 and 3.
^ must be infinity Ohms (no continuity)
- Open throttle completely.
- WOT switch must switch ON and resistance decrease to 0 Ohms (continuity)
- If NOT OK, replace CTP/WOT switch.
- Reinstall throttle body. Use new throttle body gasket, Part No. 026 133 073B. Gasket must be positioned to cover vacuum channel.