Intake Manifold

Intake Manifold

Special tools, testers and auxiliary items required

• Torque wrench (5-50 Nm) (VAG 1331)

• Socket and extended bit (T10107A)

Removing

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

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

- First, check whether a coded radio is installed. If necessary, obtain the anti-theft code.

- With the ignition switched off, disconnect the battery ground (GND) cable.

- Remove the engine cover.

CAUTION!
Fuel system is under pressure!

• Wear protective goggles and protective clothing to prevent injuries and contact with skin.

• Before loosening the line connection, place a cloth around the connection point. Then release pressure by carefully loosening the line connection.

Vehicles through Model Year (MY) 2009





- Remove the vacuum line - 1 -, ventilation line - 2 - and fuel supply line - 3 - and catch any leaking fuel with a clean cloth.

Vehicles from MY 2010

- Remove the ventilation line - 2 - and fuel supply line - 3 -. Catch any leaking fuel with a clean cloth.

Continuation for All Vehicles

• Press the securing ring to disengage the lines.

- Disconnect all connectors - 1 - from the fuel injectors as well as connectors - 2 and 6 -.





- Remove the wiring harness - 3 - from the transport strap.

- Pull all clamps - 4 - and retaining ring - 5 - from the locking mechanism.

- Remove bolts - 7 - and remove the transport strap.

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

• Coolant hoses are only for a throttle valve control module heated by coolant

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





- Remove the wiring harness - 2 -. To do so, carefully press off clips - arrows -.

- Bring the lock carrier into service position. Radiator Support


- Support lock carrier using a sleeve - B -, 80 millimeters (mm) in length, for example, from (VW 540/1 A) and a M8 x 100 bolt - A -.





- Remove nut - 1 - for the line - 2 - for the power steering at the engine and disconnect the line from the threaded pin.





- Remove the oil dipstick out of the intake manifold and press retaining ring - 4 - downward.

- Remove the oil dipstick guide tube from the bottom of the cylinder block.

- Cover the opening in the cylinder block.

- Loosen the intake manifold bolts - arrows - using (T10107A).





Bolts remain in the intake manifold.

- Remove the intake manifold upward at an angle.

Make sure that no bolts fall out.

- Seal the intake passages in the cylinder head using clean cloths.

- Reinsert the guide tube for oil dipstick into the cylinder block and secure it.

If the manifold must be replaced:

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

- Disconnect the vacuum hose for the Leak Detection Pump (LDP) (V144).

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

Installing

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

• Replace the seals between the intake manifold and cylinder head.

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

• Replace the oil dipstick guide tube O-ring.

- Bleed the fuel supply system. Refer to one of the following:

• Engine code BPS, refer to => [ Fuel System, Bleeding ] .

• Engine code BPR, refer to => [ Fuel System, Bleeding ] Description and Operation.

- Connect the battery.

Tightening Specifications