Intake Manifold

WARNING: This page is about a different car, the 2006 Volkswagen Jetta and 2005 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Hose clamps up to 25 mm dia. 3094
Torque wrench V.A.G 1331
Torque wrench V.A.G 1410
Spring-type clip pliers VAS 5024A

Removing

-- Remove engine cover.

One Piece Engine Cover

Fig 1: Identifying Removal Of One Piece Engine Cover

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Pull the one piece front engine cover -arrows A- upward with a quick jerk and then pull the lower mount -arrow B- forward.

Selecting Diagnosis Function

Fig 2: Identifying Removal Of Two Piece Engine Cover

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

On the two piece engine cover, first pull the outer cover upward with a quick jerk -arrows in the upper illustration-, then pull the inner engine cover upward with a quick jerk -arrows in lower illustration-.

NOTE:

The hoses -2- remain connected.

Fig 3: Identifying Bolt And Clips To Remove Air Duct

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove air duct. To do this slightly lift the clips -1- and remove the bolt -3- from the transport strap.

-- Disconnect connector -arrow- at intake flap motor -V157-.

Fig 4: Identifying Intake Flap Motor V157 Connector & Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove bolts -1 to 3 - and remove intake flap motor -V157-.

-- Remove intake connection with EGR potentiometer -G212- and EGR vacuum regulator solenoid valve -N18-, refer to INTAKE CONNECTION WITH ELECTRICAL EGR VACUUM REGULATOR SOLENOID VALVE AND POTENTIOMETER .

-- Remove the turbocharger, refer to TURBOCHARGER .

-- Remove intake manifold -arrows-.

Fig 5: Identifying Bolts To Remove Intake Manifold

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Installing

Installation is performed in reverse order. When doing this note the following:

NOTE:

Always replace gaskets and seals.

Observe installed position of intake manifold gasket.

Pay attention to the information when installing the air guide pipe to the connector, refer to WITH CONNECTION COUPLINGS .

Secure all hose connections with hose clamps.

-- Fill with coolant, refer to COOLING SYSTEM, DRAINING AND FILLING .

Tightening Specifications

Component		Nm
Intake manifold to cylinder head		22
Engine lifting eyelet to cylinder head		20
Bracket to intake manifold		10
Connecting pipe to intake manifold connection bolt		22
EGR cooler to intake manifold		10
Intake Flap Motor -V157- to intake manifold		10