Volkswagen Touareg 2004-06

Intake Manifold

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Removal & Installation



3.2L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the ignition coils from the spark plug holes.
  4.  
  5. Remove the intake hose between the Mass Air Flow (MAF) sensor and the throttle body.
  6.  
  7. Unplug the 6-pin connector from the throttle body, as well as the 2-pin connector from the EVAP canister purge valve and crankcase breather valve.
  8.  
  9. Label and remove the vacuum hoses from the intake manifold.
  10.  
  11. Remove the securing bolt from the intake manifold support.
  12.  
  13. Unbolt the intake manifold supports from right and left side of the intake manifold.
  14.  
  15. Disconnect the crankcase breather hose from the cylinder head cover.
  16.  
  17. Remove the bolts from the two remaining brackets on the intake manifold.

    Click image to see an enlarged view

    Fig. Remove the bolts from the two remaining brackets on the intake manifold-3.2L engines

  18.  
  19. Pull off the vacuum hose from the intake manifold vacuum actuator.
  20.  
  21. Unbolt the coolant pipe on the front of the cylinder head.
  22.  
  23. Remove the intake manifold securing bolts.
  24.  
  25. Remove the manifold and place it on a suitable surface so that the vacuum actuator is not damaged.
    NOTE
    Seal the intake ports in the intake manifold and in cylinder head with clean cloths.

  26.  
  27. Installation is the reverse of removal. Observe the following torque specifications:

    Intake manifold: 10 ft. lbs. (13 Nm)
     
    Intake manifold supports: 15 ft. lbs. (20 Nm)
     
    Oil dipstick: 5 ft. lbs. (8 Nm)
     

  28.  

4.2L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove the intake hose from the throttle body.
  6.  
  7. Remove or disconnect any components necessary to ease access to the intake manifold.
  8.  
  9. Disconnect the fuel supply line.
  10.  
  11. Unplug the injector wiring harness and set aside.
  12.  
  13. Remove the bolts securing the intake manifold.
  14.  
  15. Remove the manifold and place it on a suitable surface so that it is not damaged.
    NOTE
    Seal the intake ports with clean cloths to prevent entry of foreign objects.

  16.  
  17. Installation is the reverse of removal. Observe the following:

    Set new gaskets in place, then install the alignment cones and pins. Tighten to 26 inch lbs. (3 Nm)
     
    Tighten the intake manifold bolts to 7 ft. lbs. (10 Nm)

    Click image to see an enlarged view

    Fig. Exploded view of the intake manifold-4.2L engines

     

  18.  

 
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