Intake Manifold

Intake Manifold

Special tools, testers and auxiliary items required

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

• Socket and Extended Bit (T10107 A)

Removing

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

• Pay attention to the rules of cleanliness. Refer to => [ Clean Working Conditions ] Multiport Fuel Injection.

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

- Disconnect the battery.

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


The fuel system is under pressure!

• Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin.

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

- Disconnect the vacuum line - 2 - if present, the ventilation line - 1 - and the fuel supply line - 3 -.






To release the lines - 1 and 2 -, press the circlip in.

Press the circlip upward into the housing to release the line - 3 -.

- Seal the lines so that the fuel system is not contaminated by dirt, etc.

- Disconnect the connectors - 1, 2 and 6 -.






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

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

- Remove the bolts and remove transport strap.

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

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






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

- Pull the 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 - on the guide tube.






- Lay the guide pipe - arrows - aside.






- Open the clip - arrow - on the leak detection pump (V144) vacuum hose.






- Remove the intake manifold bolts - arrows - from the cylinder head using the socket and extended bit (T10107 A).






The 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 a clean cloth.

If the manifold is being replaced:

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

- Disconnect the vacuum hose for the leak detection pump.

- Remove the manifold absolute pressure 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 from the inside, working toward the outside in a diagonal sequence.

- Connect the battery.

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

Tightening Specifications