Volkswagen Workshop Service and Repair Manuals

Removing and installing intake manifold Special tools and workshop equipment required

t  Torx socket T30 -T10405- Removing   WARNING t  Read rules for cleanliness and the instructions for working on the fuel system → Chapter. t  Always follow these rules for cleanliness and instructions before starting work and while working on the fuel system. –  Remove engine cover panel → Chapter. –  Remove noise insulation → General body repairs, exterior; Rep. gr.66.

–  Remove air intake hose. To do this, loosen hose clip -2-.

–  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.

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

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

–  Unscrew bolt -2- and union nuts -1, 3-; remove high-pressure line. –  Removing fuel rail → Chapter.

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

–  Open and remove clip -1-.

–  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 „Assembly overview - intake manifold“.   Note Renew seals and gaskets. –  Tighten bolts from inside out in diagonal sequence. –  Install air pipe. –  Installing fuel rail → Chapter. –  Install noise insulation → General body repairs, exterior; Rep. gr.66.