Removal and installation the intake manifold of a diesel SDI engine (VW Golf 4)

SDI Diesel Engine Intake Manifold

• 1 - upper part of the intake manifold;
• 2 - screw, 10 Nm;
• 3 - Allen bolt, 15 Nm;
• 4 - O-ring. A new O-ring must be used when installing;
• 5 - lower part of the intake manifold;
• 6 - exhaust gas recirculation valve;
• 7 - Allen bolt, 25 Nm;
• 8 - Seal. A new seal must be used during installation;
• 9 - Allen bolt, 20 Nm;
• 10 - to the air filter;
• 11 - Intake manifold valve motor;
• 12 - bracket

When working on the cylinder head, it is sufficient to remove only the upper part of the intake manifold.

Removal

1. Remove the pipe connecting the intake manifold and the air filter.

2. Disconnect the electrical connector from the intake manifold valve motor (11).

3. Unscrew the upper part of the intake manifold (1) and remove the seal (4).

4. Remove the lower part of the intake manifold. At the same time, unscrew the clamp securing the exhaust gas recirculation valve in the intake manifold.

5. Unscrew the lower part of the intake manifold from the cylinder head.

Installation

1. Clean the mating surfaces of the intake manifold and cylinder head.

2. Replace all seals.

3. Further installation is carried out in the reverse order of removal.