Volkswagen Golf/Jetta 2 manual

Inlet manifold - removal and refitting
Fuel and exhaust systems - K-Jetronic fuel injection - 8 valve engines / Inlet manifold - removal and refitting


Note: Access to many of the fastenings and fittings of the manifold, on the bulkhead side in particular, is not good due to the close proximity of adjacent components. It may therefore be found necessary to at least partially disconnect and remove the engine/gearbox unit to gain access to certain items and allow clearance for manifold removal.

Modification: As from September 1984, components associated with the inlet manifold were modified (see illustration). All work procedures remain as follows for engines manufactured before that date (see illustration).

23.0a Inlet manifold and injection components (except engine codes PB and PF)
23.0a Inlet manifold and injection components (except engine codes PB and PF) Ц from September 1984

23.0b Air cleaner, inlet manifold and associated components Ц pre September
23.0b Air cleaner, inlet manifold and associated components Ц pre September 1984

Removal
1 Disconnect the battery earth lead and decompress the fuel system.

2 Disconnect the accelerator cable from the throttle valve and support/adjuster bracket on the manifold.

3 Disconnect the wiring connector and the vacuum hose from the auxiliary air valve.

4 Disconnect the wiring and detach the warm-up valve.

5 Undo the hose clips and detach the vacuum hose from the connection on the end of the manifold (left side) and the rear side of the throttle valve housing (see illustration).

23.5 Vacuum hose-to-cylinder connector
23.5 Vacuum hose-to-cylinder connector

6 Disconnect the vacuum hoses from the front of the throttle housing, noting their connections.

7 Disconnect the injectors and hoses from the cylinder head, release them from the location clips and fold them back out of the way.

8 Unclip and detach the inlet ducting from the throttle housing.

9 Remove the bolts and disconnect the support bracket from the accelerator cable support/adjuster bracket and from the cam cover.

10 Disconnect the cam cover-to-inlet manifold breather hose.

11 Undo and remove the inlet manifold retaining bolts then carefully lift the manifold, together with the throttle housing, away from the cylinder head. Disconnect any wiring or hose connections still attached as it is withdrawn.

12 The throttle housing can be unbolted from the manifold and then withdrawn from it.

Refitting
13 Refitting is a reversal of the removal procedure. Check that all mating faces are clean and use new gaskets. Tighten the securing bolts to the specified torque settings.

14 When reconnecting the accelerator cable, ensure it is correctly adjusted.

15 Check that all connections are secure and correctly made before restarting the vehicle.


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