Service Procedure

Service

Clean MAF sensor element and install breather valve kit Part No: 037 198 002

- Obtain radio code.

- Note customer's preset radio stations.

- Ensure ignition is switched OFF.

- Disconnect Battery Ground (GND) Strap.

MAF sensor, cleaning

- Remove intake air duct (between MAF sensor and throttle body) and discard.

- Remove MAF sensor.

- Carefully clean MAF sensor from both sides using a solvent based electronic cleaner which is safe on plastics and leaves no residue, such as Part No. ZVW 805001 or equivalent. One can will clean approx. 2-3 MAF sensors.

CAUTION!
The MAF sensor film is very delicate. DO NOT touch the film during repair. DO NOT use any harsh cleaners such as carburetor cleaners. Always read and follow precautions listed on cleaner container. DO NOT use compressed air to dry. This will damage the MAF sensor.

- Inspect air cleaner for oil saturation and replace if necessary.

- Reinstall MAF sensor.

Breather valve, installing





- Disconnect bottom vacuum hose from side of intake manifold.

- Disconnect top vacuum hose from side of intake manifold to fuel pressure regulator.

- Cut top hose 6O mm from fuel pressure regulator.

- Shorten remainder of hose to 50 mm, insert green plastic vacuum "T" between two hoses and reinstall hose to top port on intake manifold with clamp.

- Install previously removed bottom vacuum hose to open port of green plastic vacuum "T" with clamp (this leaves bottom port of upper intake manifold free).

- Install new intake air duct (between MAF sensor and throttle body) and connect to breather valve.





- Install support (A) on fuel line, route vacuum hose from new breather valve into clip as shown and connect to bottom vacuum port of intake manifold with clamp.

Electrical harness, installing

- Remove lower panel below fuse/relay panel.

- Lower fuse relay panel.





- Remove body plug (approx. 4O mm) located near brake booster (arrow).

- Insert harness (with fuse, black and brown connectors) through body panel to inside of vehicle.

- Fully seat grommet into body panel.





- Route brown connector behind fuse/relay panel bracket and insert into center ring of brown ground lug (arrow) at A-pillar.





- Connect fused black connector to open terminal in black 4 point TV block located above fuse relay panel or clipped to steering column bracket.

Note:
If black 4 point TV block has no open terminal replace with Part No. 3A0 937 517 (8 point TV block).

When connected, relay should activate with ignition key in the ON position only.

- Reinstall fuse/relay panel and lower panel.





- Route harness with existing engine compartment harness to right side of vehicle behind blackplastic harness cover (arrows).





- Plug connector into resistor for newly installed valve and tie-wrap harness as shown

- Connect Battery Ground (GND) Strap.

- Code radio.

- Reprogram customer's preset radio stations.