VR6 Manifold removal

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VR6 Manifold removal

Postby admin » Wed May 10, 2006 12:09 pm

::: UPPER MANIFOLD :::

First things to do are get some of the 'clutter' out of the way.

1.
Remove the spark plug wires. Use the spark plug wire tool or you highly risk damaging the plug wire ends on the spark plug side.

2.
Remove the engine cover pieces. On the right above the coil pack, and the one that partialy covers the throttle body.

3.
Remove intake tube.
Pop it open, set the filter somewhere safe. Loosen the clamp that holds the intake tube on the throttle body. Remove the hose that comes from the Idle Stabilizer Valve (ISV) that connects to the back side of the intake tube elbow. Unplug the Mass Air Flow (MAF) sensor. The air intake tube should now lift out. Set it aside.

4.
Remove throttle cable.
remove the slack adjustment clip and hold the throttle open to let enough slack through to get the cable out of the braket. Unclip the cable end from the throttle body, and remove the cable.

5.
Loosen the hard metal line from the Exhaust Gas Recirulation (EGR) valve to the throttle body. Loosen it at the throttle body side, leave it on the EGR side.

6.
Remove the two small coolant lines that attatch to the throttle body.

7.
Unplug the Electrical connections on the intake manifold and throttle body.

8.
Remove the Throttle Boddy.
Four allen screws hold it on to the manifold. Remove the Throttle Body and set somewhere safe. No is a good time to clean the gunk out of it too.

9.
Remove the allen screws that hold the intake manifold to the support brackets on the back.

10.
Remove the allen screws on the fron side of the intake manifold.

11.
Double check that all hoses and wires are disconected from the intake manifold. Lift off manifold.

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::: LOWER MANIFOLD :::
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1.
Remove all allen bolts holding the lower manifold to the head. If your tools can't reach them all due to the position of the alternator, it will have to be removed.

2.
Remove bolts holing the fuel rail on to the manifold.

3.
Unplug wires that go 'through' the manifold to the oil pressure / temp sensors.

4.
Lift out the lower manifold.

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taken from http://www.vwhowto.com/vwhowto/
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