How to Remove and Install and Clean a MK4 TDI Intake Manifold Jetta Golf Beetle

This video details the process of removing and cleaning the intake manifold on a MK4 TDi

[@alanzarycki9380]

You did a very nice job with both video and commentary. You stayed on point, were concise, yet plenty of description. How you managed video during this shoot was impressive. Thank you for taking the time to place this on the internet.

[@Littleblackrocket]

The hanger is a great tip, I'll definitely be using that next time

[@benjaminkessler8169]

get a steel cable and open one end up like a brush. then either use it by hand or drill. it works amazingly

[@mudpuppy318]

I put my intake manifold on my small propane BBQ on high for a couple hours, boy did that make a lot of smoke but it cleaned out like brand new! Super easy and I took the turbo apart while that was doing it's thing on the BBQ

[@daveleighton4683]

Brake fluid will soften the carbon very nicely and if you ream it with a bottle brush it will be as good as new in no time . A final rinse with turpentine or paraffin will finish the job. I worry about heating the manifold in case it warps.

[@Rgh71fish]

Anticipating picking up a '99.5 ALH Jetta in a few days. This will be the first thing I do. Great channel👍👍

[@MikeF421]

A '96 jetta came in that wouldn't get out of it's own way. Intake was so plugged only about an inch opening to breathe through. Used a hacksaw blade to scrape the majority of the crud out. It was stiff enough to scrape, and flexible enough to follow the runners. Used oven cleaner, gas grill, and pressure washer to finish it up.

[@100Aces]

We have 2 golfs with the ALH… thanks for the info!!! And the process is easy, unless you have a beetle… if so… add 12 steps to any job you have to do!

[@Dan23_7]

I have a beetle…. Kill me now 😂😂 Every single job on the engine is a pain. Apart from checking the oil.

[@Scott-vs9qq]

Blank the EGR pipe at one (or both) ends and use an oil catch can between the crank case vent and the intake manifold. It will significantly reduce the build up of this gunk in future.

[@TimLenhartTech]

WOW that engine needed to be steam cleaned, huh? My car doesn't have EGR or ASV, but I watched you remove them anyway as I was enjoying the pace of the video.

[@johnfitbyfaithnet]

Thank you for sharing this important information listening from Brownwood Texas your explanation is very good, "Beetles are the devil" haha

[@wacky0pker]

What gaskets are needed? Just the intake manifold gasket to the cylinder head. Also, do you apply any sealants around the gaskets?

[@stitcha123]

Did you ever find out?

[@rotaecho]

No sealant on the intake gaskets. The raised side goes towards the intake manifold with the indented side going towards the head

[@Cdevries88]

What do you do to clean the intake ports in the head if they are clogged up?

[@malcolmyoung7866]

Usually the process on the engine intake involves using small pick sets and scrapers for the DIY'er. It is important not to allow any of the debris to fall into the cylinders. The suggestion is to work on each cylinder inlet in turn and use the crank to close both the inlet and exhaust valves together. You can check they are both closed by trying to blow into the cylinder using a hose. There should be no air escaping. It is important that before opening the next inlet that the one you were working on is as clear/clean as can be from debris... Professional solutions involve blasting the valve stems and inlets with crushed walnut or similar media. Obviously this will be more thorough but the process requires strict cleanliness in the inlet after blasting and complete confidence that both the inlet and exhaust valves are closed before proceeding.

[@MiDnYTe25]

It's important to note that an aluminium intake manifold will probably deform if you heat it up this way, so you should try to remove the gunk using grease cleaner, or brake cleaner.

[@mudpuppy318]

BBQ works great! Nice even heat and bakes the stuff into a powder

[@debidirocco5633]

I’m at my end here I know a lil about cars but I have a 1.9 lt beetle bug and it’s a TDI 5 speed. It’s only has 145,000 miles 1999, and I changed a lot of stuff on my car but it was running great then on day it clicked a few times and died it’ll turn over I did replace timing belt that’s fine but my car has been down 7 months PLEASE HELP ME PLEASE.

[@markmd9]

@@debidirocco5633 what help do you expect, are you planning to repair it yourself? Either you give it to professionals to do the job or you should learn it's construction and buy the needed tools and pieces yourself.

[@K2edg]

Is this a safe way of doing it? was the intake - head mating surface still flat and not warped after heating it up like that??

[@katscan9114]

Didnt see or hear about gaskets until the end. Intake manifold gasket? Is there one

[@liammorris8756]

Hi Ryan, great work pal, just wondering if or when you'll be doing a turbo strip and clean, I have a seat leon pd150. thanks again.

[@maxpowa1646]

Hello, did you notice any difference after this process?

[@CharlesMSmith-jc6kp]

Is this an automatic or manual gearbox? Are the intake manifolds identical for 2003 Jetta TDI?

[@fakename-m6s]

All of these videos say be careful not to round off the Allen bolts. Well I rounded 2 of them it is easy to do. Anyone have any advice how to get them out now?

[@zaratrusta79]

All in all great video, but doesn't all that turbocharged flame overheat the metal, causing it to degrade/make it more brittle (even if you don't melt it)? Think I'd rather use some mechanical process like a dremel with flexible cable and proper sanding/cleaning accessories...

[@zaratrusta79]

ps. I realize that's a part that will anyway have gone through hundreds or thousands of high heat cycles, but I still doubt it will normally reach the temperatures caused by a direct flame like that... would be interesting to test that.

[@Hockeymyk]

what about using muriatic acid or white vinegar or like lemon or lime juice instead of diesel or gas?

[@ryancurran5801]

I unplugged the coolant hose on the egr and it started spilling coolant all over the place? I held a cup to it for 5 min and it wont stop coming out

[@eniscotton8592]

i have a 2006 jetta wagon tdi ---it shakes on acceleration ease up on pedal shake goes away any ideas

[@austinrudd463]

I have 4 of the 6 manifold bolts out. The last 2 stripped out

[@adamsorell4851]

all that crap is because of egr?

[@andrefell5116]

Hi would you take the inlet manifold off a vw caddy

[@TimLenhartTech]

I am working on a Beetle also, is removing the cowl absolutely necessary?

[@blockphi]

No. It’s a pain in the arse with it left on, but it is doable.

[@Dan23_7]

I have a beetle, yep they’re the devil, any job inside the engine bay requires rubber arms and fingers. I’m doing inlet clean when I replace the turbo in nicer weather (oil in the pipe work 😢) Mine is the ATD pd 2003. The cowl with the wipers looks a bithhh to get remove and that’s just the start 🤦🏼‍♂️😂

[@jonathanaguilar1946]

is that the same process in vw sharan 2004 mod.??

[@francomanca]

Very helpful! I was trying to remove the valve cover and the most hidden Allen head svkcrew was difficult to reack.. No finger soave... So I've just fuvket it up... And now to remove that I have to take the intake manifold off... Unless something creative comes to my mind... Anyhow.. Thanks for the video

[@bobbydhal2199]

Awesome Video

[@neil.s4287]

Mr muscle oven cleaner works a treat for this job.

[@Whatinthewoke]

Neo Star You should not get it on aluminum parts

[@user-dn6qy1ou1f]

@@Whatinthewoke exactly. It will eat away aluminum!

[@leonardborgesx]

Is there an intake gasket? Wondering about reinstalling and what is needed. Thanks

[@kev_tsi1164]

Yes

[@ksasbr107]

Hello ✋🏻, you didn't show how you take that pipe out at 03:00 , because I have leak in my car LandRover LR3 V8 4.4 leak in the PCV and I tried to replace the PCV but couldn't remove the pipe ? It's the same hose in your car at 03:00 how you remove it ? And what's the name of it ? Thank you

[@ksasbr107]

Also you can see the pipe or hose whatever it name at 07:30

[@martyjansing2675]

are you using gasket sealer on intake manifold gasket, manifold to head? if so what kind?

[@rickydub6950]

Thanks for posting 👍

[@kontraverzni]

nice video 👍

[@anthonylocsei9716]

Oven cleaner works well w/o heating. Takes some time.

[@YULABEBE]

thanks for this excellent walkthrough.

[@takmaisim8511]

U a king

[@Smittyschannel]

How does flaming it not warp the manifold???

[@REDRAMV10]

It does warp.

[@davekana8388]

I was concerned about warpage as well!

[@shamskl3245]

OMG i cant believe it is your Turbo still working? hahahaha

[@creepscast]

Egr valves are the devils work, just delete them they do more damage than they are worth. I deleted my egr and cleaned my intake out with traffic film remover and the pressure washer above 200 degrees

[@russellshireman]

You wanna do another? I'll pull one of my spares off for ya and you can check out the new car

[@jonathanchinchilla5907]

Exactly how mine is right now lol

[@barlux88]

I broke my ball allen tip off in one of the intake bolts 🤬🤬🤬🤬🤬

[@user-dn6qy1ou1f]

Use a rounded bolt extractor socket if you haven't already got it off. And lost of penetrating fluid next time!

[@JoeZelensky]

Should have deleted the EGR.

[@p4jrogue945]

Le mec nous met en titre mk4 il nous sort sa new Beetle ok ces le même moteur mais faut pas confondre mk4 et cette merde

[@allanmccullough8550]

I wouldn't touch that job without cleaning that nasty thing first. The owner should be ashamed to have let it get in that state.

[@snaxgalore5764]

do people really not know how to edit audio to not only be in one of my freaking ears

[@robh1908]

That is actually caused from a bad maf.

[@billymays7376]

Rob H egr and diesel exhaust has loads of particulate

[@mred9335]

only real men wear crocs!

[@RyanVWDiesel]

Yea, with my feet they are one of the few things that are comfortable.