Volkswagen Eurovan 2000-03

Intake Manifold

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Removal & Installation





Click image to see an enlarged view

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

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the engine top front cover.
  6.  
  7. Remove the engine insulation cover.
  8.  
  9. Drain the engine coolant into an approved container.
  10.  
  11. Disconnect the coolant hoses at the radiator.
  12.  
  13. Remove the 3 screws at the top of the front grille.
  14.  
  15. Remove the intake hose between Mass Air Flow (MAF) sensor and the throttle valve control module.
  16.  
  17. Remove the two top bolts on each side that support the lock carrier.
  18.  
  19. Fold the lock carrier forward , along with the radiator assembly.
  20.  
  21. Disconnect the connectors to the ignition coils with power output stage and move the wiring harness clear.
  22.  
  23. Remove the ignition coils using T10094 extractor.
    1. Remove or disconnect:
    2.  



    Connector from throttle valve control module..
     
    Coolant hoses from throttle valve control module and plug hose ends.
     
    Center support between intake manifold and heat shield/exhaust manifold.
     
    Pressure hose at combination valve and connecting hose at cylinder head cover.
     
    Unclip pressure hose and all other lines from retainers at intake manifold and at cylinder head cover.
     
    Intake manifold supports at both sides at bracket from heat shield/exhaust manifold.
     
    Secondary Air Injection (AIR) pump motor.
     
    Dipstick and dipstick tube.
     
    Intake manifold with throttle valve control module.
     

  24.  

To install:

  1. Install the intake manifold(s) to the cylinder head with a new gasket(s). Tighten the bolts to 18 ft. lbs. (25 Nm)
  2.  
  3. Reverse the removal procedure to install remaining components.
  4.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the engine top front cover.
  6.  
  7. Remove the engine insulation cover.
  8.  
  9. Drain the engine coolant into an approved container.
  10.  
  11. Disconnect the coolant hoses at the radiator.
  12.  
  13. Remove the 3 screws at the top of the front grille.
  14.  
  15. Remove the intake hose between Mass Air Flow (MAF) sensor and the throttle valve control module.
  16.  
  17. Remove the two top bolts on each side that support the lock carrier.
  18.  
  19. Fold the lock carrier forward , along with the radiator assembly.
  20.  
  21. Disconnect the connectors to the ignition coils with power output stage and move the wiring harness clear.
  22.  
  23. Remove the ignition coils using T10094 extractor.
    1. Remove or disconnect:

      Connector from throttle valve control module..
       
      Coolant hoses from throttle valve control module and plug hose ends.
       
      Center support between intake manifold and heat shield/exhaust manifold.
       
      Pressure hose at combination valve and connecting hose at cylinder head cover.
       
      Unclip pressure hose and all other lines from retainers at intake manifold and at cylinder head cover.
       
      Intake manifold supports at both sides at bracket from heat shield/exhaust manifold.
       
      Secondary Air Injection (AIR) pump motor.
       
      Dipstick and dipstick tube.
       
      Intake manifold with throttle valve control module.

      Click image to see an enlarged view

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

       

    2.  

  24.  

To install:

  1. Install the intake manifold(s) to the cylinder head with a new gasket(s). Tighten the bolts to 18 ft. lbs. (25 Nm)


  2.  
  3. Reverse the removal procedure to install remaining components.
  4.  

 
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