Volkswagen Cars 2000-05

Intake Manifold 2

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Removal & Installation



Gasoline Engines
  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.

    Click image to see an enlarged view

    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



    Click image to see an enlarged view

    Fig. Exploded view of the intake manifold mounting and related components-2.5L (BGP/BGQ) engine



    Click image to see an enlarged view

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



    Click image to see an enlarged view

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

     

  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 (ATQ) engines: 7 ft. lbs. (10 Nm)
     
    2.0L (ABA/AEG/AVH/AZG/BDC/BEV/BGD) engine upper and lower mounting bolts: 15 ft. lbs. (20 Nm)
     
    2.5L (BGP/BGQ) engines: 71 inch lbs. (9 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.  

 
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