Checking intake manifold change-over: VW Golf IV / Bora (ADR, AEB, AFY, AGN, …)

🧭 Before you start

Inspect the vacuum lines and hoses and test the system for leaks. Disconnect the actuator hose from change-over valve 1, connect the hand pump to tester connection B and the actuator to connection A, set the tester to A/B and pump to no more than 500 mbar; if vacuum drops, renew the upper manifold part. Repeat on valve 2 for the lower part. If both hold, remove the upper manifold, check the change-over components move freely, repeat the leak test with flap movement observed, and renew the faulty part.

Fits: VW Golf IV / Bora (1J)

Don't miss

• Check line routing and hose porosity before blaming the actuators.
• Do not exceed 500 mbar of vacuum with the hand pump.
• Vacuum must not drop; any drop condemns that manifold section.
• The change-over valve is integrated in the manifold and not visible from outside.
• Confirm the flaps actually move during the repeat test.

Written for this job from the workshop steps below · TorqFix editorial.

🔧 Engine codes this applies to

📐 36 workshop diagrams for ADR

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. Check vacuum lines to make sure they are connected properly and .
2. Check vacuum hoses for porosity.
3. Test vacuum system for leaks.
4. Pull vacuum hose to actuator for intake manifold changeover (arrow) off intake manifold changeover valve (1). [Note: The actuator for the variable intake manifold change-over valve is integrated in the intake manifold and is not therefore visible from the outside.]
5. Connect hand vacuum pumpVAS 6213 to vacuum testerV.A.G 1368 -connection B-.

6. Connect vacuum hose for vacuum unit to vacuum testerV.A.G 1368 -connection A-.
7. Set vacuum tester to -A/B- position.
8. Operate hand vacuum pumpVAS 6213 several times. Create a vacuum of maximum 500 mbar.
9. Vacuum must not drop.
10. Renew upper part of intake manifold .
11. Pull vacuum hose to actuator for intake manifold changeover (arrow) off intake manifold changeover valve 2 (1).
12. Connect hand vacuum pumpVAS 6213 to vacuum testerV.A.G 1368 -connection B-.
13. Connect vacuum hose for vacuum unit to vacuum testerV.A.G 1368 -connection A-.
14. Set vacuum tester to -A/B- position.
15. Operate hand vacuum pumpVAS 6213 several times. Create a vacuum of maximum 500 mbar.
16. Vacuum must not drop.
17. Renew lower part of intake manifold .
18. Check mechanical change-over components in intake manifold for ease of movement.
19. Remove upper part of intake manifold.
20. Repeat leakage test on both vacuum actuators. Check whether change-over flaps move.
21. Renew upper or lower part of intake manifold.

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