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Pelican Technical Article:

Lower Intake Manifold Removal

Jared Fenton

Time:

2 hours2 hrs

Tab:

$12

Talent:

****

Tools:

5mm/6mm Allen head drivers

Applicable Models:

Jetta MkIV 2.0L (1998-05)

Parts Required:

Lower intake manifold gasket

Hot Tip:

Use a long 6mm Allen head driver to reach the upper bolts.

Complementary Modification:

Replace spark plugs

Certain projects on the AVH 2.0 require removal of the lower intake manifold. The procedure for removing it is relatively easy once the various items around the engine have been removed. This includes the upper intake manifold, the secondary air pump and the alternator. Please see our articles on Upper Intake Manifold Removal, Secondary Air Pump Removal and Alternator Removal for more information.

When installing the lower intake manifold, be sure to use a new gasket between the manifold and the cylinder head. Take a few minutes to clean the mating surfaces and do not use any sealing compound.

Begin by removing the 5mm Allen bolt (green arrow) securing the dipstick bracket to the manifold.
Figure 1

Begin by removing the 5mm Allen bolt (green arrow) securing the dipstick bracket to the manifold. Then loosen and remove the 6mm Allen head bolt (purple arrow) securing the bracket to the manifold.

From above the manifold, loosen and remove the two 6mm Allen head bolts (green arrows) and the two 13mm nuts (purple arrows) securing the manifold to the cylinder head.
Figure 2

From above the manifold, loosen and remove the two 6mm Allen head bolts (green arrows) and the two 13mm nuts (purple arrows) securing the manifold to the cylinder head.

From below the manifold, loosen and remove the four 6mm Allen head bolts (green arrows) securing the manifold to the cylinder head.
Figure 3

From below the manifold, loosen and remove the four 6mm Allen head bolts (green arrows) securing the manifold to the cylinder head. At this point, you should be able to remove the manifold.

A long 6mm Allen driver as shown here (green arrow) helps to remove the two inner bolts on the top of the manifold.
Figure 4

A long 6mm Allen driver as shown here (green arrow) helps to remove the two inner bolts on the top of the manifold.

Remove the old manifold gasket from the mounting studs.
Figure 5

Remove the old manifold gasket from the mounting studs. Be sure to replace the gasket every time the manifold is removed.

And here's the finished result, with the manifold removed.
Figure 6

And here's the finished result, with the manifold removed. Re-installing the manifold is the reverse order of disassembly.

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Page last updated: Mon 12/5/2016 03:06:46 AM