Intake Manifold: Service and Repair
Intake Manifold
Removing
Special tools and workshop equipment required
• Torque Wrench (5-50 Nm) -V.A.G 1331-
Note:To perform this procedure, the ground cable must be disconnected from the battery. Check whether a coded radio is installed. If so, obtain the anti-theft code beforehand.
- Turn off ignition and disconnect the ground cable from the battery.
- All cable ties which are opened or cut off when removing, must be replaced in the same position when installing.
- Remove the engine cover.
- Remove the ignition coils with power output stages for cylinders 1 through 6 using the puller for ignition coil -T10095 A- Service and Repair
- Remove the connecting pipe between the mass airflow sensor -G70- and throttle valve control module -J338- Locations
- Disconnect the 6 pin connector from the throttle valve control module -arrow-.
- Unscrew the ground connection from the throttle valve control module.
Warning: Hot steam may escape when opening the expansion tank cap. Wear protective goggles and protective clothing to prevent damage to eyes and scalding. Cover the cap with a cloth and open carefully.
- Open and close the cap on the expansion tank, to relieve the cooling system pressure.
- Disconnect the coolant hoses from the throttle valve control module and plug the hose ends.
- Remove the coolant and connecting lines as well as the vacuum connections, behind the intake manifold.
- Disconnect the vacuum lines -arrows- from the intake manifold.
- Unbolt the intake manifold supports from the right and left of the intake manifold.
- Remove the bolt -1- for the intake manifold support.
Warning: 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. Wrap a cloth around the connection before removing a fuel hose. Then release pressure by carefully disconnecting the connection.
- Disconnect the supply line -1- (white or with a white mark) and return line -2- (blue or with a blue mark) and catch any leaking fuel with a shop cloth.
Note: Press the buttons together on the hose connections to do so.
- Seal the lines so that the fuel system is not contaminated by dirt, etc.
- Unclip the fuel and vacuum lines at the cylinder head cover.
- Remove the two sideways bolts for the intake manifold support.
- Remove the noise insulation, along with the left and right sides.
- Remove the front bumper cover. Service and Repair
- Remove the retaining clamp(s) from the refrigerant lines.
Warning: Do not open the Air Conditioning (A/C) refrigerant circuit.
- Bring the lock carrier into the service position. Lock Carrier, Moving to Service Position
- Disconnect the vent hose from the cylinder head cover.
- Unclip the pressure hose and all addition lines from the retainers on the intake manifold and cylinder head cover.
- Remove the oil dipstick guide tube bolt -1- from the intake manifold.
- Unclip the Secondary Air Injection (AIR) solenoid valve -2- and the variable intake manifold valve -2- at the vacuum reservoir.
Note: The connectors for the valves can remain connected.
- Disconnect the vacuum hose from the intake manifold changeover vacuum actuator.
- Remove the bolts for the intake manifold from the cylinder head.
- Remove the intake manifold and place it on a suitable surface so that vacuum actuator is not damaged.
Note: Seal the intake passages in the intake manifold and in the cylinder head with clean cloths.
Installing
- Installing is carried out in the reverse order while noting the following:
Note:
• First, bolt the intake manifold to the cylinder head. Then, install both intake manifold support bolts.
• Make sure the fuel hoses are secure.
- Fill with coolant Service and Repair