Variable Induction Position Sensor: Service and Repair

Intake Flap Motor (V157) with Intake Manifold Runner Position Sensor (G336)

Special tools, testers and auxiliary items required

• Assembly Tool (T10118)

• Commercially available 1/4" Reversible Ratchet, for example Hazet 2264

• T30 TORX(R) Bit

Removing

- Remove the engine cover with air filter. Refer to => [ Engine Cover with Air Filter ] Engine Cover With Air Filter.

- Remove the air duct bolts - arrow - and duct from the lock carrier.






- Remove the turbocharger recirculation valve - 1 - with the intermediate flange and remove the hose. Refer to => [ Charge Air Cooler Overview ] Charge Air Cooler Overview.






- Remove the vacuum lines - arrows -.






- Disconnect the following connections:

• It is easier to open connectors that are hard to access when using the assembly tool (T10118).

• Intake flap motor connector

• EVAP canister purge regulator valve 1 connector

• Manifold absolute pressure sensor connector

• Throttle valve control module connector

• Low fuel pressure sensor connector

- Disconnect the connectors - arrows -.






- Loosen the wiring bracket - A - and move the wiring harness to the side.

- Remove the bracket for the connector from the coolant pipe - arrows -.






• Loosen the nut with the left arrow just enough so that the bracket can moved to the side.

• Plastic brackets are attached.

• To improve clarity, the intake manifold is shown removed in the graphic.

- Pry the connecting rod - arrow - off the intake flap motor.






- Remove the bolts - 1 and 2 - using the 1/4" reversible ratchet T30 TORX(R) bit.

• The rear bolts - arrow - can only be removed with the reversible ratchet. The space between the bolt and coolant pipe is very small.






- Remove the intake flap motor from the intake manifold.

Installing

Install in reverse order of removal. Note the following:

- Position the bolts - 1 and 2 - by hand to avoid damaging the threads.






- Install the turbocharger recirculation valve. Refer to => [ Charge Air Cooler Overview ] Charge Air Cooler Overview.

If the intake flap motor or intake manifold was replaced, the intake manifold runner position sensor must be adapted to the Engine Control Module (ECM). Refer to "Guided Functions" in the vehicle diagnostic tester.