Volkswagen Golf/Jetta/Cabriole 1990-1999

Intake Manifold

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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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