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Pelican Technical Article:
Throttle Body Cleaning and Replacement

Steve Vernon

 
Time: 1 hour
Tab: $325-$425
Talent:  
Tools:
5mm Allen, pliers
Applicable Models:
Touareg (2004-07)
Parts Required:
O-ring, throttle body
Hot Tip:
You can learn how your engine is running by looking at the throttle body
Performance Gain:
Smoother-running engine
Complementary Modification:
New air filter
 
   

   
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     The throttle body on the Volkswagen Touareg is a precision piece of equipment that is subject to a rather harsh environment. After years of reliable service, the throttle body may become dirty or clogged, which may result in lowered performance. A simple good cleaning may be all that is needed to restore performance and improve mileage. You may find that there is a lot of built-up dirt, particularly if a previous owner didn't change the air filter too often. Be sure to check your intake plenum boots for cracks while the throttle body is off and replace if necessary.

     The throttle body is relatively easy to remove and clean. Before you begin work, make sure that you have a new throttle body O-ring. Even if you are just taking the throttle body off to clean it, you will need to install a new O-ring when you put it all back together.
The throttle body is located on the right rear side of the intake manifold (red arrow).
Figure 1
The throttle body is located on the right rear side of the intake manifold (red arrow).
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You will need to disconnect the air intake tube from the MAF sensor to remove the tube and while they make a special set of pliers to remove the clamp you can also use a set of large regular pliers (red arrow).
Figure 2
You will need to disconnect the air intake tube from the MAF sensor to remove the tube and while they make a special set of pliers to remove the clamp you can also use a set of large regular pliers (red arrow).
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Use the pliers to release the clamp on the air intake tube to throttle body (yellow arrow) and remove the intake tube from the body.
Figure 3
Use the pliers to release the clamp on the air intake tube to throttle body (yellow arrow) and remove the intake tube from the body. Next unplug the wiring connection for the throttle (red arrow).
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There are four 5mm Allen bolts that hold the throttle body to the intake manifold; you will need to reach around behind the throttle body and remove these.
Figure 4
There are four 5mm Allen bolts that hold the throttle body to the intake manifold; you will need to reach around behind the throttle body and remove these. This photo shows the location of the bolts in the body (red arrows). The bolts are ridiculously long so be prepared for it. With the bolts removed you can lift the body out from the engine compartment for cleaning or replacement.
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If you are just cleaning your throttle body make sure to get all of the oil and residue off both the butterfly valve and plenum (red arrow).
Figure 5
If you are just cleaning your throttle body make sure to get all of the oil and residue off both the butterfly valve and plenum (red arrow). If the throttle body is really oily it is a sign of problems with the motor like a bad air oil separator.
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There is an O-ring between the throttle body and manifold.
Figure 6
There is an O-ring between the throttle body and manifold. Whether you are just cleaning the manifold or replacing it, always install a new gasket (red arrow); this is not and area you want unmetered air getting through. Installation is the reverse of removal.
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Need to buy parts for this project?
Click here to order parts for your Volkswagen from our parts catalog
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  Applies to: Touareg (2004-07)
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