Intake Manifold Bolts

Tyler E

Veteran Member
Joined
Jan 26, 2011
Location
North Carolina
TDI
2000 Jetta 1.9 TDI
I am going to clean out my intake manifold and heard that the bolts my strip, so i am trying to find a place online where i can order replacement Intake Manifold Bolts just in case

so far i have had no luck finding someone who sells them

2000JettaTDI
 

eb2143

Top Post Dawg
Joined
Dec 26, 2005
Location
Rhode Island
TDI
None
idparts recently put one together, and is a little closer to you.
http://idparts.com/catalog/product_info.php?products_id=2357

Also sell bolts individually. I don't think I've ever rounded one out in two changes of my intake. Make sure the hex head is all the way seated and stays seated as you begin to torque them. I'd get a fiber gasket and EGR o-ring in any case, so probably makes sense to get the kit.
 

tdidieselbobny

Top Post Dawg
Joined
Apr 4, 2005
Location
Stafford,NY (WNY)
TDI
'03 Galactic Blue Jetta TDI, '15 Silk Blue Golf Sportwagen TDI
And if for some reason you do round it out,tap a 12 point 12mm socket over head of bolt if you don't have one of those bolt remover sockets.
 

AndyBees

Top Post Dawg
Joined
May 27, 2003
Location
Southeast Kentucky
TDI
Silver 2003 Jetta TDI, Silver 2000 Jetta TDI (sold), '84 Vanagon with '02 ALH engine
I've had several Intakes off and no stripped bolts. They are Allen head bolts and you need the correct size tool.

I always insert the tool, give it a whack with a hammer and they break loose without much effort.

The Oil line to the Turbo on the left side (driver's side) and the two piece heat shield (right side of exhaust manifold) will be an issue. The oil line brace needs to be loosened and pulled out of the way. The two piece heat shield will need to be removed............allows better access to at least two of the Intake bolts.

In the photo below, you can see where the heat shield is bolt onto the right side of the Exhaust manifold. If you look close, you can see the brace that supports the oil feed line to the Turbo.

The Intake bolts are in the head .........no Intake of course!


Another view
 
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Tyler E

Veteran Member
Joined
Jan 26, 2011
Location
North Carolina
TDI
2000 Jetta 1.9 TDI
Thanks for all the tips so far they have been very helpful

One more question a while back i took off my egr valve and cleaned it -which took longer to clean it than to take it off and re-install it. What is the best way to clean the intake manifold any tips please I've heard of a chemical bath (but i worry about leftover residue blowing seals) and the "Fire" Method (Which seams to work the best but It looks easy to overheat the manifold and crack it) or the safe alternative but very time consuming steel brushes
 

whitedog

Veteran Member
Joined
Jul 12, 2004
Location
Bend, Oregon
TDI
2004 Jetta that I fill by myself
The best way is the way that you are most comfortable with. You are worried about residue with a chemical bath, but that's really a non-issue if you pressure wash it with clean water when done. Heat can be a bit scary, and you don't sound comfotable with that, so what does that leave you?

You knew the answer. :)
 

gquenstedt

Veteran Member
Joined
May 26, 2006
Location
San Antonio, TX
TDI
'06, '03 x 2, '00
The best way I have found is to take it to a machine shop and let them clean it in their heated parts washer. Much easier that way and well worth the money in my opinion.
 

AndyBees

Top Post Dawg
Joined
May 27, 2003
Location
Southeast Kentucky
TDI
Silver 2003 Jetta TDI, Silver 2000 Jetta TDI (sold), '84 Vanagon with '02 ALH engine
If I owned a machine shop, TDI Intakes would be prohibited from being placed in my tank cleaner ............LOL.

I knock out all the crud I can with my 1500 psi pressure washer. Then, I install a cap & gasket on the EGR end of the Intake. Then, I place it on a flat surface so that all four ports are facing up and level. Then, I pour in Awesome cleaner 100% strength (totally full).....let it soak for a week or longer..........followed by another pressure wash!

Of course, you really need an extra Intake to do as I have explained.
 

Aridzonan

Member
Joined
Mar 22, 2007
Location
Cave Creek, AZ USA
TDI
2001 GOLF
Removing Intake Manifold Questions

Gentlemen, great info. I've got a 2001 TDI Golf. Just replaced the EGR valve and I almost fainted when I saw the amount of gunk that was in the intake manifold. I've got a "limp mode" problem. But, the only engine code I'm throwing is P0380,"Glow Plug". So, I'm planning on removing and cleaning the intake manifold first before I do anything else. Any other tips, tricks on locating the intake and removing manifold bolts? From what I've read I should soak each bolt in WD40, etc. before I attempt removal.
 

whitedog

Veteran Member
Joined
Jul 12, 2004
Location
Bend, Oregon
TDI
2004 Jetta that I fill by myself
From what I've read I should soak each bolt in WD40, etc. before I attempt removal.
If you were in the rust belt, maybe some WD would be fitting, (though probably not) But in AZ. the thing to do is work at getting a good whack on the end of the bolt or on the allen socket you are using. You need a good, straight whack, so a bent allen wrench isn't goin to help.

Most likely when you get the bolt out, you will se that the threads are nice and clean with no rust, showing that the WD isn't needed.

So my question to folks is how does the whack help? I haven't figured it out, I just know that it does help.
 

Ski in NC

Top Post Dawg
Joined
Jul 7, 2008
Location
Wilmington, NC USA
TDI
2001 Jetta ALH 5sp stock
I think over years and many thermal cycles, the bolt head where it seats makes a bond, either by corrosion or something on the microscopic scale. You notice it when a bolt "snaps" when breaking free and it rattles your hands!!

My theory is some of that bond is broken when you whack it. I try to whack sideways with a drift pin, but if straight-on is the only option, then straight-on it is.
 

Tyler E

Veteran Member
Joined
Jan 26, 2011
Location
North Carolina
TDI
2000 Jetta 1.9 TDI
Here's what i ended up getting:

1 x Intake Manifold Gasket (A3)(B4)(A4)(B5.5) (alh_intake_g) = $1.99
6 x Intake Manifold Bolt (A4 ALH) (alh_im_bolt) = $5.94
 

whitedog

Veteran Member
Joined
Jul 12, 2004
Location
Bend, Oregon
TDI
2004 Jetta that I fill by myself
For a buck apeice, it will be nice to have them there with you. Take the left over good ones to the next GTG and if someone is doing an intake cleaning and they need some bolts, you can be a hero.
 

AndyBees

Top Post Dawg
Joined
May 27, 2003
Location
Southeast Kentucky
TDI
Silver 2003 Jetta TDI, Silver 2000 Jetta TDI (sold), '84 Vanagon with '02 ALH engine
For a buck apeice, it will be nice to have them there with you. Take the left over good ones to the next GTG and if someone is doing an intake cleaning and they need some bolts, you can be a hero.

2X ^^ .......... and also hang on to the old Intake gasket! If someone does an Intake cleaning/swap at a GTG and breaks their gasket, you can also be their hero!

I can only recall one time ever breaking Intake Bolts on a VW diesel .......it was an old 1.5 Liter with 1000s and 1000s of heat and cool cycles! Seems we broke three of the six bolts!

Whack 'em first, as already stated several times! My Dad, his brother, my uncles (all career mechanics), etc., wacked bolts that were known to be stubborn! The viberations from the whack breaks the bond as someone mentioned!
 
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