Intake Manifold Upper Part, Removing and Installing

Intake manifold upper part, removing and installing
Engines: BBW, BEV, BHP
Special tools and equipment





- 3094 Hose clamps





- VAS 5024 Assembly tool for spring-type clips
- V A G 1331 Torque wrench (5 to 50 Nm)

Removing

CAUTION: When performing repair work, especially due to the confined conditions in the engine compartment, pay attention to the following:
^ Route all types of lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum) as well as electrical wiring so that the original positions are restored.
^ Ensure sufficient clearance to all moving or hot components.

Note: During this work procedure the battery Ground strap must be disconnected Therefore, please check whether a coded radio is installed Obtain the radio code first if necessary

- With ignition switched off disconnect battery Ground strap.
- Remove engine cover.

WARNING: Hot steam can be released when removing the cap from the expansion tank. Always cover the cap with a cloth and open it carefully.

- Open cap on coolant expansion tank.





- Clamp-offhose-3-.

Engine: BHP
- Pull off hoses -1- and -3-.

Engines: BBW, BEV
- Pull off hoses -1-, -2- and -3-.





- Disconnect connector -1- and pull off hoses -4-, -5-, -6- and -7-.

Engine: BHP
- Pull off hoses -5- and -7-.

Continue for all engines
- Release clamps -3- and -8- and remove intake hose -2-.
- Disconnect connector from throttle valve control module.
- Remove rear bolts from warm air deflector plate and front bolts from intake manifold lower part.
- Remove intake manifold lower part, with connected coolant hoses to throttle valve control module and vacuum hose to brake booster, and lay to side.

Note:
^ Seal the intake ports in the intake manifold lower part with clean cloths.
^ To remove the intake manifold upper part, remove the throttle valve control module and vacuum hose from the brake booster.

Installing
Installation is performed in reverse order to removal, note the following:
- Considering installed position, replace intake manifold lower part seal.
- Adapt (match) engine control module to throttle valve control module, Refer to Adapting components and functions.
- Generate readiness code again if DTC memory has been erased or engine control module was disconnected from permanent positive, Refer to Adapting components and functions.