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Pelican Technical Article:

Intake Manifold Removal

Jared Fenton

Time:

1 hour1 hr

Tab:

$0

Talent:

***

Tools:

5mm/6mm hex drivers, hose clamp pliers, telescoping magnet

Applicable Models:

VW Jetta GL (1999-05)
VW Jetta GLS (1999-05)
VW Jetta Wolfsburg (1999)

Parts Required:

Intake manifold

Hot Tip:

Remove the throttle body for better access to mounting bolts

Performance Gain:

Access to components underneath

Complementary Modification:

Replace valve cover gasket

Certain projects on the Mk4 Jetta 2.0 require you to remove the intake manifold for access. Removing the manifold isn't difficult, but there are a few connections you may miss if you're not looking for them. In this article, I'll go over the steps involved with removing it.

Keep in mind that you may find it easier to access one of the mounting bolts by removing the throttle body. See our article on Cleaning Throttle Body for more information.

Move to the left rear of the intake manifold.
Figure 1

Move to the left rear of the intake manifold. Pull the vacuum hose (yellow arrow) off the intake manifold. Then pull the hose (blue arrow) out of the retaining clip. Use a pair of hose clamp pliers to loosen and slide back the two connections (green arrows) shown here. You'll also need to loosen and remove the 6mm hex mounting bolt (purple arrow) behind the manifold. It is nearly impossible to get a picture of this, but you can see it if you look behind the manifold.

Shown here is the 6mm hex mounting bolt (green arrow) on the left ride side of the manifold.
Figure 2

Shown here is the 6mm hex mounting bolt (green arrow) on the left ride side of the manifold. Note that the throttle body has been removed for access.

Use the hose clamp pliers to loosen the hose clamp (green arrow) and pull the vacuum hose off the manifold.
Figure 3

Use the hose clamp pliers to loosen the hose clamp (green arrow) and pull the vacuum hose off the manifold.

Pull the vacuum hose (green arrow) off the connector attached to the manifold.
Figure 4

Pull the vacuum hose (green arrow) off the connector attached to the manifold.

Now loosen and remove the 5mm hex bolts at the front of the manifold.
Figure 5

Now loosen and remove the 5mm hex bolts at the front of the manifold. You can see the three bolts (yellow arrows) at the front edge. The two remaining bolts are accessed through slits cut into the manifold (green arrows). You'll need to use a long 5mm hex driver as shown here.

It's a good idea to use a telescoping magnet (green arrow) to hold the bolt as you loosen it.
Figure 6

It's a good idea to use a telescoping magnet (green arrow) to hold the bolt as you loosen it. This prevents you from dropping it.

Shown here is the bolt being withdrawn from behind the manifold with the magnet.
Figure 7

Shown here is the bolt being withdrawn from behind the manifold with the magnet.

Use a flathead screwdriver to carefully pull the fitting (green arrow) out of the brake booster.
Figure 8

Use a flathead screwdriver to carefully pull the fitting (green arrow) out of the brake booster. Now you're ready to remove the manifold.

And here's the final result with the manifold removed from the engine.
Figure 9

And here's the final result with the manifold removed from the engine. Installing the manifold is the reverse of removal.

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