Upper Intake Manifold, Removing and Installing

Intake manifold upper part, removing and installing
Special tools, testers, measuring instruments and auxiliary items required





^ V.A.G 1331 Torque wrench (5-50 Nm)





^ 3094 Hose clamps

Note:
^ During the further course of work the battery Ground strap must be disconnected. Check whether a coded radio is installed. Obtain radio code first if necessary.
^ Observe the notes on, Refer to Cooling System, Service and Repair, Cooling System Components, Removing and installing, See note

Removing
^ With ignition switched off disconnect battery Ground strap.
^ Release pressure in coolant circuit by opening coolant expansion tank cap.
^ Remove engine cover.
^ Remove air cleaner with intake hose and Mass Air Flow (MAP) sensor -G70.
^ Clamp off coolant hose from Throttle valve control module -J338- (with for example V.A.G. 3094).
^ Ensure following components are disconnected from coolant hoses:
^ Top of expansion tank
^ Throttle valve control module -J338-
^ Ensure following components are disconnected from electrical connections:
^ Intake manifold change-over valve -N156-
^ Positive Crankcase Ventilation (PCV) heating element -N79-
^ Throttle valve control module -J338- sender
^ Ensure following components are disconnected from breather or vacuum hoses:
^ Intake manifold change-over valve -N156-
^ EVAP canister purge regulator valve -N80- to intake manifold upper part
^ EVAP canister to intake manifold upper part
^ Injector breather lines
^ Brake servo vacuum line
^ On fuel pressure regulator
^ Vacuum line T-piece above fuel regulator





^ Remove bolts (arrows) from intake manifold upper part -1- on intake manifold support of warm air collector -2-.





^ Remove upper bolts on intake manifold
^ Remove spreader (split) rivets.





^ Press tabs -1-, as illustrated, carefully outward so that pins for spreader (split) rivets mounting -2- are free. At same time move intake manifold upper part back and forth until it can be disconnected on exhaust side.

Note: The intake manifold upper part complete with throttle valve control module can only be removed when the cylinder head cover has been removed.

^ Remove cylinder head cover.
^ Carefully remove intake manifold upper part.

Installing
^ Carefully seat intake manifold upper part onto its original position on warm air collector plate.
^ Install cylinder head cover.
^ Slide intake manifold upper part carefully onto intake manifold supports on intake manifold lower part.





^ Press tabs -1- carefully outward. Then press intake manifold upper part back onto intake manifold lower part by moving it back and forth until it seats on limit stop.
^ Install spreader (split) rivets.





^ Install bolts to intake manifold upper part on intake manifold support of warm air collector.





^ Install upper bolts on intake manifold.
The rest of the assembly is basically in reverse order to the removal sequence.