Removing and installing intake manifold (vehicles with intake manifold flap V157) — VW

Removing and installing intake manifold (vehicles with
intake manifold flap
V157
)
Special tools and workshop equipment required
Torque wrench
V.A.G 1331
Pliers
3314
Special wrench, long reach
T10405
DANGER!
Observe safety precautions when working on diesel direct injection fuel system
Chapter
.
Observe rules for cleanliness
Chapter
.
Follow these instructions before starting work and while working on system.
Removing
Remove engine cover panel
Chapter
.
Caution
Make sure that no wiring connections are damaged when disconnecting the connectors. Otherwise the whole wiring harness will need to be renewed. Do not compress the
pliers
3314
too firmly to separate the connectors, otherwise the support sleeve may be damaged.
Open cable guide fasteners
arrows
to free wiring harness.
Position
pliers
3314
with groove
arrow A
on support sleeve shoulder
arrow B
and pull plugs off glow pin plugs.
Carefully pull connector off glow pin plug in direction of
arrow
.
Unclip vacuum hoses
arrow
and lay to side.
Unscrew the securing bolts
arrows
and put the coolant return line to the side.
Unscrew the securing bolts
arrows
and put the fuel return line to the side.
Pull connector
arrow
off
intake manifold flap motor
V157
.
Pull connector off
throttle valve module
J338
2
.
Open clamp
3
.
Remove bolt from oil dipstick attachment.
Open clamp
2
on charge air pipe.
Remove the charge air hose between
throttle valve module
J338
and charge air pipe.
Open the clamp
1
on the connecting pipe for exhaust gas recirculation and remove the connecting pipe.
Unscrew the securing bolts from the intake manifold from the outside to the inside in diagonal sequence with
hexagon key extension
T10405
.
Remove intake manifold.
Installing
Installation is carried out in the reverse order. When installing, note the following:
Renew seals
Now you need to insert the securing bolts into the holes in the intake manifold.
Carefully guide the intake manifold together with the seals and securing bolts to the installation location.
Tighten the intake manifold securing bolts from the outside to inside in diagonal sequence.
Specified torques:
Chapter
, Assembly overview - intake manifold with attachments.