Passat Wagon L4-1.9L DSL Turbo (AHU) (1997)
Additional required parts must be ordered by you from your respective parts depot.
Please do not over-order any of these parts; you may be required to return excess inventory.
Work Procedure
A.
Intake Manifold Replacement
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Open hood and remove engine cover
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Disconnect pressure pipe to intake manifold and move aside (do not disconnect vacuum line)
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Disconnect and remove pressure pipe (metal air pipe) from the turbocharger
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Disconnect the vacuum line leading to the EGR valve
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Disconnect and remove the flexible air hose from the mass air flow sensor
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Remove the bolt from the air intake hose (to turbocharger) bracket on the side of the intake manifold
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Disconnect pipes (convoluted) from each end of the EGR cooler; DO NOT disconnect at exhaust manifold
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Disconnect the EGR cooler from the intake manifold and move the EGR cooler rearward.
NOTE: Do not disconnect any coolant lines.
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Remove the intake manifold with convoluted pipe attached
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Remove the convoluted pipe and stud from the intake manifold and install on the replacement intake manifold, P/N 028 129 711T, using new
gasket, P/N 069 131 547 D, and torque convoluted pipe bolts to 25 Nm (18 ft lbs.)
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Install replacement intake manifold with new gasket, P/N 028 129 717 D, (beading towards intake manifold) and torque bolts to 25 Nm (18 ft
lbs.)
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Reinstall the EGR cooler to the intake manifold and torque bolts to 10 Nm (7 ft lbs.)
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Connect the pipes (convoluted) to each end of the EGR cooler using new gaskets, P/N 028 131 547 C, and torque bolts to 25 Nm (18 ft lbs)
NOTE: Tighten all bolts finger tight (parts free to move slightly) then tighten stress free.
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Reinstall all other components in reverse order of disassembly
B.
Engine Control Module (ECM) Replacement
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Remove the weather strip on the top edge of the plenum panel
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Remove water plenum cover by turning (3) clips
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Remove the air temperature sensor including bracket
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Remove the pollen filter and plastic tray
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Disconnect the vacuum hose to the ECM
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Disconnect the wire harness connector on the ECM
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Remove ECM from the vehicle