Intake Manifold Upper Part, Removing and Installing

Intake manifold upper part, removing and installing

Special tools, testers, measuring instruments and auxiliary items required





^ VAG1331 Torque wrench (5...50 Nm)





^ Spring-type clip pliers VAS5024





^ 3094 Hose clamps

Removing

CAUTION: When performing repair work, especially due to the confined conditions in the engine compartment, pay attention to the following:
^ Route all types of lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum) as well as electrical wiring so that the original positions are restored.
^ Ensure sufficient clearance to all moving or hot components.

Note:
^ During the further course of work the battery Ground strap must be disconnected. Therefore, please check whether a coded radio is installed. Obtain the radio code first if necessary.

^ With ignition switched off disconnect battery Ground strap.
^ Remove engine cover.

WARNING: Steam can be released when removing the cap from the expansion tank. Cover the cap with a cloth and open it carefully.

^ Release pressure in coolant circuit by opening coolant expansion tank cap.
^ Remove air cleaner with intake hose and Mass Air Flow (MAP) sensor -G70.
^ Clamp off coolant hose from Throttle valve control module -J338- (with for example VAG 3094).

^ Ensure following components are disconnected from coolant hoses:
^ Top of expansion tank
^ Throttle valve control module -J338
^ Ensure following components are disconnected from electrical connections:

Engine codes BDC, BGD
^ Intake manifold change-over valve -N156-

Continuation for all engines
^ Positive Crankcase Ventilation (PCV) heating element-N79
^ ^Throttle valve control module -J338-

^ Ensure following components are disconnected from breather or vacuum hoses:

Engine codes BDC, BGD
^ Intake manifold change-over valve -N156-
^ Vacuum line T-piece from Intake manifold change-over valve -N156-

Continuation for all engines
^ EVAP canister purge regulator valve -N80- to intake manifold upper part
^ EVAP canister to intake manifold upper part
^ Injector breather lines
^ Brake servo vacuum line

Engine codes AEG, AVH, AZG, BDC
^ On fuel pressure regulator





Engine codes BDC, BGD
^ Remove bolts (arrows) from intake manifold upper part -1- on intake manifold support of warm air collector.





^ Remove upper bolts on intake manifold (arrows)
^ Remove spreader (split) rivets





^ Press tabs -1-, as illustrated, carefully outward so that pins for spreader (split) rivet mounting -2- are free. Simultaneously, move intake manifold upper part back and forth until it can be disconnected on exhaust side.

Note: The intake manifold upper part complete with throttle valve control module can only be removed when the cylinder head cover has been removed.

^ Remove cylinder head cover

Continuation for all engines
^ Remove rear bolts from warm air deflector plate and front bolts of intake manifold lower part.
^ Carefully remove intake manifold upper part.

Note:
^ Seal the intake ports in the intake manifold lower section with clean cloths.
^ To remove the intake manifold upper part, remove the throttle valve control module and vacuum hoses from the brake servo.

Installing
Installation is performed in the reverse order. When installing, note the following:
^ Carefully seat intake manifold upper part onto its original position on warm air collector plate.

Engine codes BDC, BGD
^ Install cylinder head cover.
^ Slide intake manifold upper part carefully onto intake manifold supports on intake manifold lower part.





^ Press tabs -1- carefully outward. Then press intake manifold upper part back onto intake manifold lower part by moving it back and forth until it seats on limit stop.
^ Install spreader (split) rivets.





^ Install bolts to intake manifold upper part on intake manifold support of warm air collector.





^ Install upper bolts on intake manifold.
The rest of the assembly is basically in reverse order to the disassembly sequence.

Continuation for all engines
^ Replace seal for intake manifold lower part; note installation position.
The rest of the assembly is basically in reverse order to the disassembly sequence.
^ Adapt (match) engine control module to throttle valve control module; Refer to Adapting components and functions
^ If fault memory has been erased or engine control module separated from permanent positive power supply, generate readiness code again; Refer to Adapting components and function