Upper Intake Manifold

Two Piece Intake Manifold

Upper Intake Manifold

Special tools, testers and auxiliary items required

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Assembly Tool (T10118)

Removing

• Read the safety precautions before beginning work. Refer to => [ Safety Precautions ] Fuel Supply.

• Observe the rules for cleanliness. Refer to => [ Clean Working Conditions ] Multiport Fuel Injection.

• Intake manifold overview. Refer to => [ Intake Manifold Overview ] Two Piece Intake Manifold.

CAUTION!
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

• Route all lines and wires in their original locations.

• Make sure the wires have enough clearance to all moving or hot components.

- Remove the ignition coil wiring harness cover strip.





- Place the (T10118) against the release button - arrow -, and carefully remove all the connectors from the ignition coil with power output stage.





- Press the cable duct upward using a screwdriver and move the connectors to the side.





- Disconnect the connectors - 1 -, remove the intake hose - 2 - and disconnect the connecting hose - 3 - for the crankcase ventilation from the cylinder head cover.





- Disconnect the lines - arrows - from the upper intake manifold.





- Remove the bolt for intake manifold support at the rear - 1 -.

- Remove the front intake manifold support bolt - 2 -.

- Remove the upper intake manifold to lower intake manifold bolts.





- Remove upper intake manifold downward and lay it on a suitable surface.

• Seal the intake passages inside the lower intake manifold with a clean cloth.

Installing

- Install the seals in the upper intake manifold and lightly lubricate them with clean engine oil.





- 1 - large seals

- 2 - small seals

- Install the upper intake manifold onto the lower intake manifold.

- Tighten the bolts - 1 through 5 - starting on the inside and working toward the outside. Tightening specification: 10 Nm.





- Install and tighten the bolts for the intake manifold supports.

The rest of the installation is basically a reverse of the removal sequence.

Tightening specifications, refer to => [ Intake Manifold Overview ] Two Piece Intake Manifold.