Intake Manifold

Intake Manifold

Special tools, testers and auxiliary items required

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Socket and Extended Bit (T10107A)

Removing

• Observe safety precautions. Refer to => [ Safety Precautions ] Multiport Fuel Injection.

• Observe the rules for cleanliness. Refer to => [ Clean Working Conditions ] Multiport Fuel Injection.

- Check if a coded radio is installed. Obtain the anti-theft code if necessary.

- Disconnect the battery.

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

CAUTION!
• Fuel supply line is under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before loosening the fuel lines, place a cloth around the connection point. Disconnect the connection carefully to release the pressure.

- Disconnect the breather line - 1 -, vacuum line - 2 - and fuel supply line - 3 -. To release lines - 1 and 2 - , press the circlip in. With line - 3 -, the retainer must be pressed upward in the housing.





- Disconnect connectors - 1, 2 and 6 -.





- Remove wiring harness - 3 - from transport strap.

- Pull clamp - 4 - and retaining ring - 5 - out of locking mechanism.

- Remove bolt - 7 - and remove transport strap.

- Remove the throttle valve control module (J338 ). Refer to => [ Throttle Valve Control Module ] Service and Repair. The coolant hoses remain attached.

- Disconnect connector - 1 - and hose for crankcase ventilation - 3 -.





- Remove wiring harness - 2 -. To do so, carefully pry up clips - arrows -.

- Pull oil dipstick out - 1 - and press retaining ring - 4 - downward.





- Remove the noise insulation.

- Loosen the bolts or nuts - 1 - on the bottom side of the intake manifold.





- Loosen the bolt - arrow - for the intake manifold support and guide pipe.





- Lay the guide pipe - arrows - aside.





- Open the clip - arrow - on the Leak Detection Pump (LDP) (V144) vacuum hose.





- Loosen intake manifold bolts- arrows - with (T10107A).





Bolts remain in intake manifold.

- Remove intake manifold upward at an angle.

Make sure that no bolts fall out.

- Seal the intake passages in cylinder head using a clean clothes.

If manifold must be replaced:

- Remove the fuel rail with injectors. Refer to => [ Fuel Injectors ] Service and Repair.

- Disconnect vacuum hose for LDP.

- Remove Manifold Absolute Pressure (MAP) sensor (G71).

Installing

Installation is performed in the reverse order of removal. When doing this note the following:

• Replace seals between intake manifold and cylinder head.

• Replace the oil dipstick guide tube seal.

• Tighten bolts for intake manifold starting inside working toward outside and in a diagonal sequence.

- Connect the battery.

- Bleed fuel supply system. Refer to => [ Fuel System, Bleeding ] Service and Repair.

Tightening Specification