How difficult is NB intake removal?

[rahsut]

Wanted to do an Intake & EGR cleaning on my 1998 New Beetle. When I took a look at the general area, it seemed very tight. I am sure people here have done it on New Beetles... just wanted to get some perspective on how difficult it is to get the Intake out of the car...

 

[ufoguy]

i'm not headed for the intake and EGR just yet, but i could use some information on how to open the air filter box on my NB and how to examine the snow screen. the air cleaner box fits really tight in between the battery and firewall and it isn't real evident as to how to open the box.

i know there are posts for different models but i wanted some help specifically for the NB.

the battery cover came loose and i have tried to get it to snap back into place but it won't go so i am reluctant to pull or unsnap anything i don't know about.

thanks!

cp

 

[lrpavlo]

Ufoguy
I watched Mark of Diesel do my NB. Take off the drivers side front wheel, remove the plastic fender liner (about 10 torx screws) and you'll probably need some special hose clamp removers to get the hose apart.
So hows the DSG been treating ya?

 

[MOGolf]

For more room from above:

(1) use masking tape to mark the location of the wiper blades on the windshield
(2) remove wiper blades
(3) remove plastic water deflector along the bottom of the windshield
(4) remove the lower plastic piece of the "plenum"

It's not hard, takes just a few minutes, and you get a lot more room to access everything.

 

[rahsut]

Thanks MOGolf... I will try that /images/graemlins/smile.gif

 

[VelvetFoot]

MOGolf, would that have improved access to the clutch master cylinder? I replaced my clutch hose the other day and got access by moving the cables in the raceway, which only move a short distance after taking a bunch of plastic crap, etc, off, and still a tight fit for my skinny arm.

 

[LNXGUY]

I'm going to tackle the EGR And Intake this weekend. We'll see how it goes..

Also, what do you guys use to clean the intake once its off? I was thinking of some of that orange oil stuff.... Maybe simple green?

 

[Growler]

[ QUOTE ]
For more room from above:

(1) use masking tape to mark the location of the wiper blades on the windshield
(2) remove wiper blades
(3) remove plastic water deflector along the bottom of the windshield
(4) remove the lower plastic piece of the "plenum"

It's not hard, takes just a few minutes, and you get a lot more room to access everything.

[/ QUOTE ]

would this also improve access to the vacuum lines etc. if I wanted to replace all of my lines at the same time?

'00 Nb here...

 

[soylentgreen]

Thanks for the tip. I just checked my 2002 NB's snow screen (20k miles, mainly freeway in Southern California) and it was not clogged at all. But it was a PITA to get to.

Note: the two techniques above (removing the air deflector near the winshield vs. the driver-side wheel and plastic body panel) are for different things. The first is for getting to the intake manifold near the head, the second is for accessing the snow screen that is upstream of the air filter...

 

[mgwerks]

[ QUOTE ]
i'm not headed for the intake and EGR just yet, but i could use some information on how to open the air filter box on my NB and how to examine the snow screen. the air cleaner box fits really tight in between the battery and firewall and it isn't real evident as to how to open the box.

[/ QUOTE ]
Not that simple, the Beetle is different. As hinted at previously, you have to pull the driver's front wheel (you don't have to, but it is much easier), remove the inner plastic fender well (1000 torx screws) and then remove the snowbox. In the Golf and Jetta you can do it from above - not us /images/graemlins/frown.gif

 

[MOGolf]

Removing those pieces as I posted above, improves access to anything in the rear of the engine compartment.

Growler, feel free to come over to my place if you want to work on it, or need "supervision". /images/graemlins/wink.gif

 

[Growler]

Glen, I just might take you up on this a I am still VERY new to my TDI...wouldnt mind hooking him up to the VAGCOM to see how hes running too...
I am prototyping a new silicone ALH TDI vacuum hose kit... need to document the process of re & re for the guy who is gonna be selling them.. I might just be the next Old navy on these and advertise them for him /images/graemlins/smile.gif if all is well...

Aaron

Ill PM you to see when we can GTG on this after the kit arrives.

 

[MOGolf]

Growler, I'm sure gearhead would be very interested in those vacuum lines too. Let us know when, and we'll work it out.

 

[MOGolf]

It was a pleasure meeting you, Aaron. It looks like those silver vacuum lines would compliment the Old Navy/Stanco Machine parts quite nicely. Let us know how they work out, or if they suck. /images/graemlins/wink.gif

BTW, we found out that NB owners need different lengths for hoses than the lengths previously posted for Golf and Jetta models. (We should have looked this up beforehand.) There's a need for about 1 more meter of 3.5x2 vacuum line and 1 less meter of the larger tubing.