Genuine Volkswagen GTI Intake Manifold

Volkswagen GTI Intake Manifold Parts and Q&A

• Intake Manifold
  06L-133-201-ES
  Q: What precautions should be taken when disconnecting the battery and removing the intake manifold for 4-cylinder engines on Volkswagen GTI?

  A:

  If the battery is disconnected, several systems must be re-learned before they will work properly. Begin by relieving the fuel system pressure. Disconnect the cable from the negative battery terminal. Working from above in the engine compartment, remove the engine cover or air filter housing. For 1.4L (CZTA, DGXA) models, raise the vehicle and support it securely on jackstands, then remove the engine splash shield fasteners and shield. Drain the coolant and disconnect the EVAP canister hoses to the intake manifold. Remove the throttle body and disconnect the quick-connect fitting for the vacuum hose and the coolant hose to the intake manifold, then remove the hoses. Disconnect the coolant hoses from the intake manifold and the coolant hose under the intake manifold, removing the pipe fastener. Disconnect the electrical connectors from the fuel pressure sensor, the oil pressure switch, and the canister purge regulator. Remove the intake manifold bolts and the intake manifold, and if necessary, remove the fuel supply line to the fuel pump and plug the line. For installation, use new manifold gaskets, install the intake manifold, and tighten the bolts in sequence to the specified torque, with the remainder of installation being the reverse of removal. For 2.0L (CBPA) models, disconnect the fuel supply line and cover the openings to prevent debris from entering the fuel system. Clamp off the coolant hoses leading to the throttle body and remove them. Disconnect the electrical connectors from the fuel injectors, CMP sensor, and the EVAP canister purge valve. Unclip the wiring harness and EVAP hose clamp from the intake manifold, then open the locking ring and remove the EVAP canister purge valve. Remove the oil dipstick tube-to-engine block retaining fastener and rotate the tube out of the way. The intake manifold is secured with eight bolts; unscrew them and pull the intake manifold away from the engine at a slight angle for clearance. For installation, use new manifold gaskets, install the intake manifold, and tighten the bolts in several stages, working from the center out to the specified torque, with the remainder of installation being the reverse of removal. For 1.8L and 2.0L timing chain models, if the intake manifold is removed or replaced, the intake manifold runner position sensor must be adapted or relearned to the engine control module. Raise the vehicle and support it securely on jackstands, then remove the engine lower splash shield. On 1.8L and 2.0L models, remove the cooling fan shroud. Remove the coolant tube bracket bolt and separate the tube from the end of the intake manifold. Remove the charge air cooler inlet and outlet pipes. Disconnect the electrical connectors for the cooling system under the intake manifold and disconnect the fuel supply line, then disconnect the electrical connectors from the sensors on the intake manifold. On specific models, remove the engine oil filter and the throttle body. Disconnect the vacuum pump quick-connector and the manifold runner control valve from the lower rear side of the intake manifold. Disconnect the fuel line from the high-pressure fuel pump and from the pump to the fuel rail. Remove the intake manifold support bracket bolts and disconnect the electrical connector from the intake manifold runner position sensor and the camshaft position sensors. Remove the intake manifold mounting nuts and bolts, then pull the intake manifold back from the cylinder head to access the electrical harness bracket under the manifold. Remove the harness bracket fasteners and the harnesses from the intake manifold. Remove the intake manifold from the vehicle and cover all openings. On specific models, remove the fuel rail and replace the injector seals, then reinstall the fuel rail and injectors to the intake manifold. For installation, ensure the gasket is seated around the four ports of the intake manifold using new manifold gaskets, then install the intake manifold. Install the harness bracket and fasteners on the bottom of the intake manifold, then tighten the fasteners securely. Tighten the bolts in several stages, working from the center out to the specified torque, with the remainder of installation being the reverse of removal.