VW Passat & Audi A4 1990-2000

Intake Manifold

Print

REMOVAL & INSTALLATION
1990-97 Passat Models
  1. Disconnect the negative battery cable. Remove the air duct from the throttle valve body and disconnect the accelerator cable.
  2.  
  3. On 2.0L ABA engines, remove the idle stabilizer valve, fuel pump pressure switch and the fuel injector wiring harness. Disconnect the fuel supply and return lines.
  4.  
  5. On 2.0L 9A engines with CIS-E fuel injection systems, remove the auxiliary air regulator. Remove the fuel injectors and the cold start valve without disconnecting the fuel lines.
  6.  
  7. Label and disconnect the vacuum hoses as required.
  8.  
  9. Label and disconnect any remaining wiring as required.
  10.  
  11. If equipped, disconnect the EGR pipe.
  12.  
  13. On 2.0L 9A and VR6 engines, remove the bolts to remove the upper intake manifold.
  14.  
  15. Remove the bolts and remove the manifold from the cylinder head.
  16.  



Click image to see an enlarged view

Fig. Exploded view of the head and intake manifold



Click image to see an enlarged view

Fig. Vacuum hose removal pliers such as these greatly speed up head removal



Click image to see an enlarged view

Fig. Exploded view of the intake manifold mounting and related components-1.8L engine



Click image to see an enlarged view

Fig. Exploded view of the intake manifold mounting and related components-2.0L (ABA) engine



Click image to see an enlarged view

Fig. 2.0L 8-valve upper intake manifold



Click image to see an enlarged view

Fig. 2.0L 8-valve upper intake manifold bolt locations



Click image to see an enlarged view

Fig. Lifting the upper intake manifold from its lower portion-2.0L, 8-valve engine



Click image to see an enlarged view

Fig. Upper intake manifold gasket



Click image to see an enlarged view

Fig. Location of the lower intake manifold bolts



Click image to see an enlarged view

Fig. There are a few intake manifold to cylinder head bolts that are hidden under the runners



Click image to see an enlarged view

Fig. Once all bolts have been removed, remove the intake manifold



Click image to see an enlarged view

Fig. Intake manifold to head gasket



Click image to see an enlarged view

Fig. Exploded view of the intake manifold mounting and related components-2.8L (AAA) engine

To install:

  1. On 2.0L 9A and VR6 engines
  2.  
    1. Install the lower intake manifold to the cylinder head with a new gasket. Torque the bolts to 18 ft. lbs. (25 Nm).
    2.  
    3. On 2.0L ABA and VR6 engines, if the fuel rail and injectors were removed, examine the injector O-rings and replace if damaged, brittle or cracked. Lubricate the O-rings with a light coating of fresh engine oil, then install the injectors and if removed the fuel rail.
    4.  

  3. Use new gaskets and fit the manifold or the upper manifold in place. Torque the bolts to 18 ft. lbs. (25 Nm).
  4.  
  5. On 2.0L 9A engines, if the fuel injectors were not removed, connect fuel system hoses.
  6.  
  7. On 2.0L 9A and ABA engines, if the injectors were removed, examine the injector O-rings and replace if damaged, brittle or cracked. Lubricate the O-rings with a light coating of fresh engine oil, then install the injectors and on ABA engines, if removed the fuel rail.
  8.  
  9. Connect all vacuum hoses and wiring.
  10.  
  11. If equipped with EGR, connect the EGR pipe.
  12.  
  13. Connect and adjust the throttle cable as required.
  14.  
  15. Install the remaining components and run the engine to check idle speed and ignition timing.
  16.  
  17. Check and clear any existing fault codes as necessary.
  18.  

A4 & 1998-00 Passat Models
1.8L Engine
  1. Turn the ignition switch to the OFF , then disconnect the negative battery cable.
  2.  
  3. Remove the engine covers.
  4.  
  5. Drain the engine coolant into a sealable container.
  6.  
  7. Disconnect the hose for the Leak Detection Pump (LDP).
  8.  
  9. Disconnect the accelerator pedal cable from the throttle valve control module.
  10.  
  11. Remove the air guide hose from the throttle valve control module.
  12.  
  13. Disconnect the vacuum line from the Evaporative Emissions (EVAP) canister.
  14.  
  15. Detach the brake booster vacuum hose.
  16.  
  17. Disconnect the Intake Air Temperature (IAT) sensor and the throttle valve control module.
  18.  
  19. Detach the Camshaft Position (CMP) sensor wiring harness connector.
  20.  
  21. Properly relieve the fuel system pressure.
  22.  
  23. Disconnect the fuel rail with the injectors and position it aside in the engine compartment on a clean cloth.
  24.  
  25. Disconnect the coolant hoses attached to the intake manifold.
  26.  
  27. Disconnect the crankcase breather hose at the intake manifold.
  28.  
  29. Remove the intake manifold brace and the oil dipstick.
  30.  
  31. Unbolt the manifold at the mounting flange, then remove.
  32.  
  33. Stuff clean shop rags into the cylinder head ports to prevent debris from entering the engine.
  34.  
  35. Clean all gasket surfaces of any old gasket material.
  36.  

To install:

  1. Remove the rags from the cylinder head ports.
  2.  
  3. Install the intake manifold with new gaskets and tighten the mounting fasteners to 84 inch lbs. (10 Nm).
  4.  
  5. Connect the manifold brace and tighten the bracket mounting bolts to 15 ft. lbs. (20 Nm).
  6.  
  7. Install the dipstick.
  8.  
  9. Connect the crankcase breather and coolant hoses to the intake manifold.
  10.  
  11. Replace the fuel injector sealing O-rings, lubricate the O-rings with a light coating of fresh engine oil, then install the fuel rail with the injectors and tighten the retaining bolts to 88 inch lbs. (10 Nm).
  12.  
  13. Connect the CMP and the IAT sensors to the throttle valve control module.
  14.  
  15. Connect the brake booster and EVAP canister vacuum hoses.
  16.  
  17. Connect the air guide hose and the accelerator pedal cable to the throttle valve control module.
  18.  
  19. Connect the hose for the LDP.
  20.  
  21. Top off the engine coolant and bleed as necessary.
  22.  
  23. Reconnect the negative battery cable.
  24.  
  25. Fully close all power windows to stop, operate all window switches for at least 1 second in the close direction to activate the 1-touch opening/closing function.
  26.  
  27. Check the oil level before starting the engine, and top off as necessary.
  28.  
  29. Enter the radio security code.
  30.  
  31. Set the clock to the correct time.
  32.  


NOTE
Diagnostic Trouble Codes (DTCs) may be stored when harness connectors are detached.

  1. Read the DTCs and clear the fault codes.
  2.  



Click image to see an enlarged view

Fig. To remove the crimped vacuum hose clamp, first insert a suitable pick tool into the crimped opening, then . . .



Click image to see an enlarged view

Fig. . . . move the pick from side . . .



Click image to see an enlarged view

Fig. . . . to side while pressing inward on the pick. If necessary insert a small flat blade screwdriver and repeat the process until the clamp is sufficiently loose. Once removed, replace the clamp

A4 & 1998-00 Passat Models
2.8L V6 Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Disconnect the fuel supply and return lines.
  6.  
  7. Detach the fuel injector electrical connectors and the retainers for the fuel injectors.
  8.  
  9. Remove the fuel pressure regulator clamp, then the regulator.
  10.  
  11. Unbolt and remove the fuel manifold, then the injectors.
  12.  
  13. Label and detach any hoses or connectors associated with the intake manifold.
  14.  
  15. Remove the upper intake manifold mounting bolts, then the manifold and gasket.
  16.  
  17. Remove the Idle Air Control (IAC) valve.
  18.  
  19. Disconnect the EGR valve.
  20.  
  21. Disconnect the accelerator cable form the throttle body.
  22.  
  23. Remove the lower intake manifold mounting bolts, then the manifold.
  24.  
  25. Clean all gasket mating surfaces of old gasket material.
  26.  
  27. Place shop rag in the cylinder head openings to prevent dirt and debris from entering the open port.
  28.  



Click image to see an enlarged view

Fig. Exploded view of the fuel injector assembly-2.8L V6 Engine



Click image to see an enlarged view

Fig. Exploded view of the upper/lower intake manifold assembly and related components-2.8L V6 Engine

To install:

  1. Remove the shop rags from the cylinder head openings.
  2.  
  3. Install the lower intake manifold using a new gasket, and tighten the mounting bolts to 15 ft. lbs. (20 Nm).
  4.  
  5. Connect the EGR valve.
  6.  
  7. Attach the accelerator cable to the throttle body.
  8.  
  9. Install the IAC valve and tighten the mounting bolts to 84 inch lbs. (10 Nm).
  10.  
  11. Install the upper intake manifold and tighten the short mounting bolts to 84 inch lbs. (10 Nm) and the long mounting bolts to 15 ft. lbs. (20 Nm).
  12.  
  13. Attach any hoses or connectors that were removed.
  14.  
  15. Install the fuel injectors using new O-rings, lubricate the O-rings with a light coating of fresh engine oil, then install the fuel manifold and tighten the mounting bolts to 88 inch lbs. (10 Nm).
  16.  
  17. Install the pressure regulator and clamp.
  18.  
  19. Install the fuel injector retainers, and then attach the electrical connectors.
  20.  
  21. Attach the fuel return and supply lines.
  22.  
  23. Connect the negative battery cable.
  24.  
  25. Check and clear any stored fault codes.
  26.  

 
label.common.footer.alt.autozoneLogo