How to remove inlet manifold 2.0 TDI 170 ps, CAHA 2011

[Sambor11]

Hi guys! Can anybody know procedure how to remove inlet manifold on this engine? Inlet manifold is made of some plastic material. I would like get to swirl flaps see their condition.

[dan2485]

You need to remove the fuel pump fuse and turn over the engine to drop the high fuel pressure in the common rail.

Then You need to remove the glow plug leads.

Then undo the dipstick from the throttle valve.

Then you need to remove the fuel pump feed and return pipes, then undo the egr cooler pipe to the egr valve.

Now remove the injector fuel pipes.

Undo the electrical connections to the throttle valve/egr valve/fuel pressure sender & fuel pressure regulator.

Then remove the Manifold intake motor plug.

Then remove the air intake hose from the throttle valve.

Then undo the bolts holding the intake in place.

You should now be able to take the intake off.

This takes about 1-2 hours dependent on how good with spanners you are.

When rebuilding get new gaskets and tighten the bolts to the correct torques.

Intake bolts 8Nm
EGR cooler bolts 20Nm
All the bolts on the egr/throttle valve are 10Nm

Once rebuilt you need ideally VCDS and run a fuel transfer test 3 time to pressurize the system (it can be done without it but this may drain your battery).

If no VCDS then disconnect the battery before unplugging anything.

[Sambor11]

Thank you dan2485! Turn over engine you mean just start engine for short time after removing fuse?

[dan2485]

Thank you dan2485! Turn over engine you mean just start engine for short time after removing fuse?


That's it.

Get 2 pipe clamps for the fuel rail pipes and clamp them in the hose section this where you disconnect them as they are clipped onto the pump.

The injector pipes need to be tightened to 25 Nm don't over tighten them as you can deform the joint and this will affect the fuel delivery pressure.