VW Golf GTI 2.0 inlet manifold removal

[scrappy_doo]

Got a Golf 2002 2.0 GTI that needs the rocker cover gasket, spark plugs and leads that need changing. Rather than the common metal inlet manifold, it has a plastic one that I'm struggling to find any DIY how to conplete this and looking at it isn't giving me any clues either! Anyone got any tips please?

[Crasher]

There are four different 2L 8v engines used in these cars with two designs of plastic inlet manifold, could we have your engine type code please?

[scrappy_doo]

Believe it is AZJ

[Crasher]

The VW instructions state rather over simplistically to "remove top part of intake manifold" and only gives this as instructions

[scrappy_doo]

Thanks for that crasher, still as you say not the clearest job in the world! Has anyone got experience of completing the job?

[Crasher]

Yes I have done quite a few over the years of both designs, it takes about an hour.

[scrappy_doo]

Any tips? Doesn't seem that obvious in the diagram exactly where the fasteners are!

[scrappy_doo]

Job completed! The main retaining bolts are at the front of the inlet manifold butn you'll need to move the air pump out the way to see them. There are 8 at the front (2 of them are 13mm nuts and the other 6 are 6mm allen bolts). Then you need to remove the throttle body (4 x 5mm allen bolts, watch out because one is longer than the rest). Then once the throttle body is out of the way you'll now be able to see a 5mm allen bolt that acts as a peg that fits inside a bushing that holds the rear of the inlet manifold (near the bulkhead) in place.

You'll now be able to remove the inlet manifold which you'll have to angle slightly to remove it off the rear peg bushing and voila access to the spark plugs, leads and rocker cover! I've not mentioned the removal of varous electrical connections and the odd pipe here and there as it's obvious when you do it!