Upper Intake Manifold

Upper Intake Manifold

Removing






- Disconnect the negative battery cable (3).

- Disconnect the engine wiring harness electrical connector from the intake air temperature sensor.

- Loosen the air cleaner outlet duct clamp at the throttle body.

- Remove the air cleaner outlet duct from the throttle body.






- Disconnect the EVAP hose from the throttle body.

- Disconnect the engine wiring harness electrical connector (1) from the throttle body.






- Disconnect the brake booster hose from the intake manifold.

- Disconnect the engine wiring harness electrical connector from the manifold absolute pressure sensor (1).

- Disconnect the positive crankcase ventilation hose.






- Remove the exhaust gas recirculation tube bolts and tube from the intake manifold.






- Remove the intake manifold bolts (1) and remove the upper intake manifold (4).

- Cover the lower intake manifold with a suitable cover while the upper manifold is removed.

- Clean and inspect the upper intake manifold.

- Remove the MAP sensor bolts (3) and sensor (2), if replacing the manifold.

Installing


The special screws used for the composite manifold attached components must be installed slowly using hand tools only. This requirement is to prevent the melting of material that causes stripped threads. If threads become stripped, an oversize repair screw is available. For more information and procedure.








- If the manifold was replaced, install the MAP sensor (2) and bolts (3). Tighten the bolts to 1.7 Nm (15 in lbs).

- Remove the covering from the lower intake manifold and clean the sealing surfaces.

- Inspect the manifold seals (6). The seals can be reused, if not damaged. Position the new seals (6) into the channels in the manifold and press lightly in place. Repeat the procedure for each seal.

- Place the upper intake manifold (4) onto the lower manifold.






- Apply Volkswagen genuine parts lock and seal adhesive (medium strength thread locker) to each upper intake manifold bolt. Install and tighten bolts in the sequence shown to 12 Nm (106 in lbs).






- Connect the engine wiring harness electrical connector to the MAP sensor (1).

- Connect the brake booster hose to the intake manifold.







The special screws used for attaching the EGR tube to the manifold must be installed slowly using hand tools only. This requirement is to prevent the melting of material that causes stripped threads. If threads become stripped, an oversize repair screw is available.

- Install the EGR tube and bolts to the upper intake manifold. Tighten the bolts to 5.5 Nm (48.5 in lbs).






- Connect the engine wiring harness electrical connector (1) to the throttle body.

- Connect the EVAP hose to the throttle body.






- Install the air cleaner outlet duct to the throttle body.

- Tighten the air cleaner outlet duct clamp at the throttle body. Tighten the clamp to 4 Nm (35 in lbs).

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

- Connect the negative battery cable (3).