Volkswagen Workshop Service and Repair Manuals

Removing and installing intake manifold (vehicles with intake manifold flap -V157-) Special tools and workshop equipment required

t  Torque wrench -V.A.G 1331-

t  Pliers -3314-

t  Allen key, long reach -T10405- »Carry out the following work sequence« Removing –  Remove engine cover panel → Chapter.   Caution Make sure that no wiring connections are damaged when disconnecting the connectors. Otherwise the whole wiring harness will need to be renewed. Do not compress the pliers -3314- too firmly to separate the connectors, otherwise the support sleeve may be damaged.

–  Open cable guide fasteners -arrows- to free wiring harness.

–  Position pliers -3314- with groove -arrow A- on support sleeve shoulder -arrow B- and pull plugs off glow pin plugs.

–  Carefully pull connector off glow pin plug in -direction of arrow-.

–  Unclip vacuum lines -arrow- and lay to side.

–  Unclip coolant return hose -arrows- and place coolant line to one side. The arrangement of the coolant return hose can vary.

–  Remove securing bolts -arrows-.

–  Disconnect connector -3- from intake manifold flap motor -V157- (if there is one). Remove high-pressure accumulator → Chapter.

–  Pull connector -2- off throttle valve module -J338-. –  Remove bolt -3- from dipstick connection.

–  Remove bolts -arrows-.

–  Remove exhaust gas recirculation connecting pipe. –  To do this, open clip -1-. –  Unscrew securing bolts from intake manifold from the outside to the inside in diagonal sequence with hexagon key extension -T10405-. –  Carefully remove intake manifold. Installing Installation is carried out in the reverse order. When installing, note the following:   Note t  An intake manifold with no intake manifold flap -V157- may be installed as a replacement part, → ETKA (Electronic parts catalogue). t  Item is installed: after completing procedures, install intake manifold with no intake manifold flap -V157- → Chapter. –  Renew seals –  Now you need to insert the securing bolts into the holes in the intake manifold. –  Carefully guide the intake manifold together with the seals and securing bolts to the installation location. –  Tighten the intake manifold securing bolts from the outside to inside in diagonal sequence. Specified torque. Install high-pressure accumulator → Chapter.