Volkswagen Workshop Service and Repair Manuals

Removing and installing intake manifold (vehicles without intake manifold flap -V157-) Special tools and workshop equipment required

t  Socket Torx T 30 -T10405- Removing → Chapter „Safety precautions“ → Chapter „Rules for cleanliness“ –  Remove engine cover panel → Chapter. –  Remove noise insulation -1- → Rep. gr.50.

–  Remove air hose, loosen hose clips -1- and -2- for this.   Note Disregard -item 1-.

–  Remove bolts -arrows-. –  Loosen hose clip -2- on throttle valve module -J338-, pull air pipe off and leave in installation position. –  Disconnect electrical connectors at glow plugs → Chapter.

–  Remove exhaust gas recirculation cooler changeover valve -N345--left arrow- from bracket and lay aside.   Note Disregard -right arrow-.

–  Unscrew bolts -2-, lay coolant return line aside.

–  Unscrew bolts -arrows-, lay coolant return line aside.

–  Unscrew bolts -2-, place coolant return line to one side. Removing high-pressure accumulator → Chapter.

–  Disconnect electrical connector -2- at throttle valve module -J338-. –  Remove bolt -1- for dipstick guide tube.   Note Ignore -arrows-.

–  Open and remove clip -1-.   Note Disregard -item 2-.

–  Unscrew bolts -arrows- for intake manifold diagonally from outside to inside using socket T30 -T10405-. –  Carefully remove intake manifold. Installing Installation is carried out in the reverse order; note the following: l  Specified torque → Chapter   Note

t  If an intake manifold with intake manifold flap -V157- was installed. t  Seal off unnecessary connector -3- from intake manifold flap motor -V157- using a cap according to → ETKA (electronic parts catalogue) or other workshop materials so that the connector is watertight. t  Secure unnecessary connector -3- from intake manifold flap motor -V157- using workshop materials t  Always renew gaskets/seals. –  Tighten bolts from inside out in diagonal sequence. –  Install air pipe. –  Install high-pressure accumulator . –  Install noise insulation → Rep. gr.50.