Intake manifold, removing and installing

Removing:

NOTE: All cable ties which are released or cut open when removing must be installed in the same position when installing.

Obtain radio anti-theft code on vehicles with coded radio.
With ignition switched off disconnect battery Ground (GND) strap.
Remove engine cover.

Fig 1: Identifying Connector, Intake Air Temperature (IAT) Sensor -G42-, Throttle Valve Control Module -J338- Connector, Air Hose & Vacuum Hose

GW00015410

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect connector -3- for Intake Air Temperature (IAT) sensor -G42- and connector -4- for throttle valve control module -J338- (below throttle valve control module).
Disconnect air hose -2- from throttle valve control module.
Disconnect vacuum hose -1- from throttle valve control module (hose leads to activated charcoal filter).

Fig 2: Removing Intake Air Duct

GW00015366

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove intake air duct -arrows-.

Fig 3: Locating Connector At Camshaft Position Sensor G40

GW00000622

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull connector off Camshaft Position (CMP) Sensor -G40- (arrow).

Fig 4: Disconnecting Connectors For Injectors And Unclipping Support Bar From Fuel Rail

GW00015411

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect connectors -1- for injectors and unclip support bar from fuel rail -2-.

Fig 5: Identifying Electrical Change-Over Valve Connector, Intake Manifold Brackets & Dipstick Tube

GW00015412

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect connector -1- for electrical change-over valve on underside of bracket.
Unbolt bracket from intake manifold (-2- and -3-) and disengage dipstick tube -4-.

Fig 6: Identifying Pull Fuel Supply Line And Fuel Return Line

GW00000195

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press release tabs and pull fuel supply line -1- and fuel return line -2- off connections.

WARNING:

Fuel system is under pressure! Before opening the system place a cloth around the connection. Then release pressure by carefully loosening the connection.

Disconnect crankcase breather hose from T-piece.
Unbolt intake manifold support from intake manifold.
Pull out oil dipstick.
Unbolt intake manifold at flange and remove.

Installing:

Installation is carried out in the reverse order, when doing this note the following:

After connecting battery terminals, enter anti-theft code for radio

Refer to Radio operating instructions

Close electric windows in front doors all the way to their top positions using electric switches.
Then operate all electric window switches again for at least one second in the "close" direction to activate the automatic one-touch function.
Set clock to correct time.
Perform adaption of throttle valve control module:

Refer to

24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AMU
24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): ATC
24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AWP
24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): BEA

; Checking throttle valve control module; Performing adaption of throttle valve control module

Interrogate DTC memory:

Refer to

01 ON BOARD DIAGNOSTIC (OBD) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AMU
01 ON BOARD DIAGNOSTIC (OBD) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): ATC
01 ON BOARD DIAGNOSTIC (OBD) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AWP
01 ON BOARD DIAGNOSTIC (OBD) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): BEA

; On Board Diagnostic (OBD) of Motronic system; checking and erasing DTC memory

NOTE: DTCs will have been stored in the memory because connectors have been disconnected. Therefore interrogate and erase DTC memory after installing engine.