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Pelican Technical Article:

Removing the Intake Manifold

Steve Vernon

Time:

1 hour1 hr

Tab:

$3

Talent:

**

Tools:

16mm wrench, 13mm deep socket and driver, 3mm Allen

Applicable Models:

VW Golf GTI (2000)
VW Golf GTI 1.8T (2002-05)
VW Golf GTI 20th Anniversary (2003)
VW Golf GTI 337 (2002)
VW Golf GTI GLS (2001)

Parts Required:

New Gasket

Hot Tip:

Don't work on a hot engine

Performance Gain:

Wont leave you stranded at the side of the road

Complementary Modification:

New belt

As with most intensive engine work, you should disconnect the battery at the negative cable terminal and remove the plastic engine cover before starting. Please see our article son battery care and maintenance and how to remove the engine covers.

You will also need to remove the fuel injectors and fuel rail. Please see our article on how to remove your injectors and rail before going further.

Begin by removing the rubber intake from the throttle body as well as the small hose attached to the front of the throttle body assembly.

At the front of the engine remove the two 10mm nuts holding the vacuum lines and the two 5mm Allen bolts holding the self. With the bolts removed lift the shelf up and off the dipstick tube. Slide the shelf out of the way. Remove the 6mm Allen attaching the intake manifold to the alternator bracket.

Next remove the vacuum lines from the top of the intake manifold, and the two from underneath.

Unplug the knock sensor on the engine block below the number 1 and 2 intake runners.

Next, remove the two 10mm nuts and eight 10mm bolts that hold the manifold to the engine. You also need to remove the vacuum line through the number 3 and 4 intake runner.

Lift the intake manifold off the two lower studs and remove it from the engine. Remove the old gasket.

Carefully clean the intake port mounting area, install a new gasket and put everything back together.

Installation is the reverse of removal.

Begin by removing the rubber intake from the throttle body as well as the small hose attached to the front of the throttle body assembly.
Figure 1

Begin by removing the rubber intake from the throttle body as well as the small hose attached to the front of the throttle body assembly.

At the front of the engine remove the two 10mm nuts holding the vacuum lines (red arrows) and the two 5mm Allen bolts (yellow arrows) holding the self.
Figure 2

At the front of the engine remove the two 10mm nuts holding the vacuum lines (red arrows) and the two 5mm Allen bolts (yellow arrows) holding the self. With the bolts removed lift the shelf up and off the dip stick tube. Slide the shelf out of the way. Remove the 6mm Allen attaching the intake manifold to the alternator bracket (green arrow).

Next remove the vacuum lines (red arrows) from the top of the intake manifold.
Figure 3

Next remove the vacuum lines (red arrows) from the top of the intake manifold.

Remove the two vacuum lines from underneath.
Figure 4

Remove the two vacuum lines from underneath.

Unplug the knock sensor on the engine block below the number 1 and 2 intake runners (red arrow).
Figure 5

Unplug the knock sensor on the engine block below the number 1 and 2 intake runners (red arrow).

Next, remove the two 10mm nuts (red arrows) and eight 10mm bolts (green arrow) that hold the manifold to the engine.
Figure 6

Next, remove the two 10mm nuts (red arrows) and eight 10mm bolts (green arrow) that hold the manifold to the engine. You also need to remove the vacuum line through the number 3 and 4 intake runner (yellow arrow).

Lift the intake manifold off the two lower studs and remove it from the engine.
Figure 7

Lift the intake manifold off the two lower studs and remove it from the engine. Remove the old gasket (red arrow).

Carefully clean the intake port mounting area (red arrow), install a new gasket and put everything back together.
Figure 8

Carefully clean the intake port mounting area (red arrow), install a new gasket and put everything back together.

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Page last updated: Mon 9/25/2017 02:37:51 AM