Volkswagen Cars 2000-05

Intake Manifold 1

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Removal & Installation





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Fig. Exploded view of the head and intake manifold



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



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



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



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Fig. 2.0L, 8 valve upper intake manifold



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



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



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Fig. Upper intake manifold gasket



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Fig. Location of the lower intake manifold bolts



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



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



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Fig. Intake manifold to head gasket



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

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine cover as required.
  4.  
  5. Remove the air duct from the throttle body and disconnect the accelerator cable.
  6.  
  7. Label and disconnect the vacuum and coolant hoses as required.
  8.  
  9. Label and disconnect any remaining wiring as required.
  10.  
  11. Disconnect the fuel supply and return lines.
  12.  
  13. Disconnect any intake manifold support brackets.
  14.  
  15. If equipped, disconnect the EGR pipe.
  16.  
  17. If equipped, remove the bolts to separate the upper intake manifold from the lower intake manifold.
  18.  
  19. Remove the bolts and remove the manifold from the cylinder head.
  20.  
  21. Place clean shop rags into the cylinder head openings to prevent dirt and debris from entering the engine.
  22.  

To install:

  1. Install the intake manifold(s) to the cylinder head with a new gasket(s). Tighten the bolts as follows:

    1.8L and 2.8L (AHA) engines: 84 inch lbs. (10 Nm)
     
    2.0L (ABA and AEG) engine upper and lower mounting bolts: 15 ft. lbs. (20 Nm)
     
    2.8L (AAA) engine upper and lower mounting bolts: 18 ft. lbs. (25 Nm)
     

  2.  
  3. On 6-cylinder engines, if the fuel injectors were removed, examine the injector O-rings and replace as required. Install the injectors and rail.
  4.  
  5. Connect fuel system hoses or install the injectors now to protect the system.
  6.  
  7. Connect all vacuum hoses and wiring.
  8.  
  9. If equipped, connect the EGR pipe.
  10.  
  11. Connect and adjust the throttle cable as required.
  12.  
  13. Install the remaining components and run the engine to check idle speed and ignition timing.
  14.  
  15. Check and clear any Diagnostic Trouble Codes (DTCs).
  16.  



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



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



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



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



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



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



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Fig. Exploded view of the intake manifold mounting and related components-4.0L (BDP) engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect:

    Negative battery cable.
     
    Engine cover as required.
     
    Air duct from the throttle body and disconnect the accelerator cable.
     
    Vacuum and coolant hoses as required.
     
    Any remaining wiring as required.
     
    Fuel supply and return lines.
     
    Intake manifold support brackets.
     
    If equipped, EGR pipe.
     
    If equipped, bolts to separate the upper intake manifold from the lower intake manifold.
     
    Bolts and remove the manifold from the cylinder head.
     

  4.  

To install:

  1. Install the intake manifold(s) to the cylinder head with a new gasket(s). Tighten the bolts as follows:

    1.8L and 2.8L (AHA/ATQ) engines: 84 inch lbs. (10 Nm)
     
    2.0L (ABA/AEG/AVH/AZG/BDC) engine upper and lower mounting bolts: 15 ft. lbs. (20 Nm)
     
    2.8L (AAA) engine upper and lower mounting bolts: 18 ft. lbs. (25 Nm)
     
    2.8L (BDF) engines: 10 ft. lbs. (13 Nm)
     
    4.0L (BDP) engines: 71 inch lbs. (8 Nm)
     

  2.  
  3. On 6-cylinder engines, if the fuel injectors were removed, examine the injector O-rings and replace as required. Install the injectors and rail.
  4.  
  5. Install or connect:

    Fuel system hoses or the injectors to protect the system.
     
    All vacuum hoses and wiring.
     
    If equipped, EGR pipe.
     
    Throttle cable.
     
    Remaining components.
     

  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Label and detach any hoses and electrical connections related to intake manifold service.
  4.  
  5. Disconnect the air inlet hose.
  6.  
  7. Remove the intake manifold mounting bolts.
  8.  
  9. Installation is the reverse of removal. Use a new gasket and tighten the bolts to 18 ft. lbs. (25 Nm).
  10.  

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.  



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



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



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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

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.  



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



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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.  

Diesel Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Label and detach any hoses and electrical connections related to intake manifold service.
  4.  
  5. Disconnect the air inlet hose.
  6.  
  7. Remove the intake manifold mounting bolts.
  8.  
  9. Installation is the reverse of removal. Use a new gasket and tighten the bolts to 18 ft. lbs. (25 Nm).
  10.  

 
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