Volkswagen Golf/Jetta 2 manual
Inlet and exhaust manifolds - removal and refittingFuel and exhaust systems - carburettor models / Inlet and exhaust manifolds - removal and refitting
Inlet manifold
1 Remove the carburettor.
2 Disconnect the inlet manifold preheater wire at the in-line connector.
3 Drain the cooling system and disconnect the coolant hoses from the manifold.
4 Disconnect the manifold vacuum hoses as necessary (see illustration).
19.4 Vacuum hose connections – 1.6 and 1.8 litre with Pierburg/Solex 2E2
carburettor
5 Where applicable, disconnect the stay rod between the base of the manifold and the crankcase (see illustration).
19.5 Inlet manifold support stay - 1.3 litre
6 Undo the manifold retaining nuts and bolts (see illustration) whilst noting their respective locations, then carefully withdraw the manifold from the cylinder head.
19.6 Inlet manifold-to-cylinder head securing nuts and bolts
Note position of earth lead spade connector (arrowed) - 1.3 litre
7 Remove the gasket and clean the mating faces of the manifold and cylinder head.
8 Refitting is a reversal of the removal procedure. Use a new manifold gasket and tighten the securing nuts and bolts to the specified torque setting.
Exhaust manifold
9 Undo the retaining nut(s) and withdraw the
warm air deflector plate from the exhaust
manifold (see illustration).
19.9 Warm air deflector plate - 1.3 litre
10 On 1.05 and 1.3 litre engines, unbolt and detach the exhaust downpipe from the manifold joint (see illustration).
19.10 Exhaust downpipe-to-manifold flange connection - 1.3 litre
11 On 1.6 and 1.8 litre engines, refer to Section 20, paragraph 2.
12 Unscrew and remove the remaining manifold retaining bolts/nuts, then carefully withdraw the manifold from the cylinder head.
Remove the gasket.
13 Clean the mating faces of the manifold and cylinder head. Also the exhaust downpipe flange connections.
14 Refit in the reverse order of removal. Use a new gasket and tighten the securing nuts/bolts evenly to the specified torque wrench setting.
15 When reconnecting the downpipe to the manifold, smear a little exhaust jointing paste onto the flange prior to connection. This will ensure a good seal at the joint.
