Lower Intake Manifold

Lower Intake Manifold

Removing

- Perform the fuel system pressure release procedure. Refer to => [ Fuel System Pressure Release Procedure ] Service and Repair.

- Drain the cooling system. Refer to => [ Cooling System Draining and Filling ] Cooling System Draining and Filling.

- Remove the upper intake manifold. Refer to => [ Upper Intake Manifold ] Upper Intake Manifold.






- Disconnect the fuel line quick connect fitting - arrow - from the fuel rail.






- Remove the ignition coil nuts (3) and coil (5).

- Remove the ignition coil bracket bolt (4) and bracket (6).






- Disconnect heater supply hose.

- Disconnect the engine wiring harness electrical connector (2) from the engine coolant temperature sensor (1).






- Disconnect the fuel injector wire harness.

- Remove the fuel rail bolts - arrow -.

- Remove the fuel rail and injectors.







The Intake manifold gasket is made of a very thin metal and may cause personal injury, handle with care.

- Remove the radiator upper hose.

- Remove the lower intake manifold bolts.

- Remove the lower intake manifold (1).

- Remove the intake manifold gasket bolt (2) and remove the gasket (3).

- Inspect and clean the lower intake manifold.

Installing






- Place a bead (approximately 1/4 in. diameter) of Volkswagen genuine parts engine RTV GEN II sealant onto each of the four manifold to cylinder head gasket corners (1).






- Carefully install a new intake manifold gasket (3). Tighten the bolts (2) to 12 Nm (106 in lbs).

- Install the lower intake manifold (1) and bolts.






- Tighten the lower intake manifold bolts in the sequence shown to:

• Tighten the bolts a first pass to 1 Nm (8.8 in lbs).

• Tighten the bolts a second pass to 22 Nm (16 ft lbs).

• Tighten the bolts a final pass to 22 Nm (16 ft lbs).

- After the intake manifold is in place, inspect to make sure seals are in place.








- Install the fuel rail and injectors.

- Install the fuel rail bolts - arrows -. Tighten the bolts to 12 Nm (106 in lbs).

- Connect engine wiring harness to the fuel injectors.

- Connect the engine wiring harness electrical connector to the ECT sensor.






- Connect the heater supply hose.

- Install the radiator upper hose to the manifold.

- Connect the fuel line quick connect fitting - arrow - to the fuel rail.

- Install the upper intake manifold. Refer to => [ Upper Intake Manifold ] Upper Intake Manifold.

- Fill the cooling system. Refer to => [ Cooling System Draining and Filling ] Cooling System Draining and Filling.

- Connect the negative battery cable.