Intake Manifold: Removing

WARNING: This page is about a different car, the 2015 Volkswagen Beetle, 2014 Volkswagen Beetle, and 2013 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

Make sure no contaminants enter the fuel system when removing the intake manifold.

Seal off the connections in the fuel system using the plugs from the Engine Bung Set VAS 6122.

-- Remove the engine cover. Refer to ENGINE COVER .

-- Remove the protective strip, if equipped -item 1-.

-- Loosen the high pressure line or fuel lines -arrows- on the intake manifold.

Fig 1: Identifying Fuel Line Bolts On Intake Manifold

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-- Remove the connector on the fuel injectors -A-, the Exhaust Pressure Sensor 1 -G450- -B- and the Fuel Pressure Sensor -G247- -C-.

Fig 2: Disconnecting Fuel Injector Connectors

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-- Remove the coolant line bolts -arrows- from the intake manifold and lay the line in front of the intake manifold.

-- Unclip the wiring harness from the wiring guide for the glow plugs.

CAUTION: Always follow the procedure. Refer to GLOW PLUG CONNECTORS, REMOVING AND INSTALLING .

-- Remove the glow plug connectors GLOW PLUG CONNECTORS, REMOVING AND INSTALLING .

-- Remove the high pressure line -item 21- between the high pressure fuel pump and rail element (high pressure reservoir).

-- Loosen the hose clip -arrow- with the Hose Clip Pliers VAS 6362 and remove the line on the rail element (high pressure reservoir).

Fig 3: Identifying Hose Clamp

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-- Before removing, clean the return line connection on the fuel injectors (for example using a commercially available detergent).

-- Dry the return line connections.

-- Cover the return line connections with a rag.

-- Remove the fuel return line connections on the fuel injectors. Pull them upward to release them -arrow-.

Fig 4: Identifying Direction To Remove Fuel Return Line Connections From Fuel Injectors

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NOTE: Maintain clean working conditions. Dirt and contaminants must not enter the return lines and the connections on the fuel injectors.

-- Loosen the hose clips with the Hose Clip Pliers VAS 6362 and remove the fuel return line -item 4.

-- Loosen the hose clip -4- with the Hose Clip Pliers VAS 6362 and remove the fuel return line at the high pressure fuel pump.

Fig 5: Identifying Fuel Temperature Sensor -G81- Connector, Fuel Metering Valve -N290- Connector And Spring Clamps

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-- Seal the lines so that the fuel system is not contaminated by dirt etc.

-- Remove the fuel return lines -item 2-.

-- Disconnect the connector from the EGR Vacuum Regulator Solenoid Valve -N18- -1- and the Throttle Valve Control Module -J338- -3-.

Fig 6: Identifying Connectors

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-- Loosen the clamp -4- and remove the charge air hose.

-- Remove the oil dipstick bracket -arrow-.

CAUTION: Make sure the connecting pipe decoupling element does not bend or stretch. Cracks could develop.

-- Disconnect the connecting pipe -2-.

-- Remove the intake manifold bolts with a Socket XZN 8T40159 in a diagonal sequence working from the outside toward the inside.

-- Remove intake manifold.