sam08861

Just did this job and it wasn't so bad. Wanted to post this with part numbers and. helpful videos I found.

Including repairing the PCV membrane, this all in took ~5-6 hours, with a lot of pausing in between.

Since I had to remove everything again, as I'd been shipped the wrong injector seals, I was able to do the removal and replacement of the intakes in under 2 hours.

Some tips:

Buy the valve cover gasket, intake manifold gasket, lower injector seal kits, etc from your local VW or audi dealer before you start. If you're in a pinch on the fuel injecto o-rings, Danco #83 o-rings are made of buna-n rubber so can withstand fuel and high temp.
Use and air compressor with at least 4-5 cfm at 90psi

Parts:

Injector seal kit: $7 x 3 03H198149
Valve Cove gasket: $11 03H103483E
Intake Gasket: $7 03H133237D
PCV Gaskets: $32 from RKX Tech.

Amazon link--> . You could also get the valve cover and intake seals here in a kit. This way, you'd just need the injectors.

Other items:
Harbor freight protable media blaster: $23
Walnut fine media (harbor freight): $30. I used maybe 3-5 pounds of the 50 pound box. Could have got this cheaper too with another trip, but used my 20% off on the blaster.

There's a youtube video where most of this is shown and there are 3 parts, so I won't get into pics. I watched the 3 videos like 3 or 4 times and read all the comments before I tackled this job. Link to the 1st video... 2nd and 3rd will be the 'play next' items.


Sequence

Remove the 30A fuse #6 under the hood
Remove all the connectors to the ignition coils and undo all the retaining clips so that these can be out of the way.
Remove the hose between the airbox and throttle body
Remove the throttle body
Remove the breather valve
Remove the vaccum flap controller thingy
Remove the 3 vacuum hoses from the left side of the manifold.
Remove the 3 bolts (front, left and rear) from the brackets holding on the intake.
Remove the 4 intake manifold bolts
Remove the oil dipstick screw.
If that's taken at least half an hour, the system is depressurized and you can then remove the 2 rubber fuel hoses (17mm), which allows access to a flare nut coming from underneath on a steel tube in the rear (14mm
Then you can remove the 3 screws under the right side of the manifold that hold a steel hose, which is in the way of the 3 bolts holding the injector rails and the manifold.
Unplug the plug that's attached to the manifold near the fuel rail.

Now can negotiate the intake manifold off.

Remove the coil packs.

Remove the bolts from the valve cover. (there's a specific sequence in the video)

Remove the mechanism inside the valve cover and replace the seals. Theres a Video for this too!

You Tube

Finally, for the walnut blasting there's several videos... Here's one:
I didn't make any special tools or change the blaster wand. Just plugged all the intake holes with rags. Used plastic bags and clothes pins on the injector openings and put a towel over the intake. Sure made a mess, but my leaf blower made short work of everything when all was said and done.

By the way, to close the valves as you go from set to set, turn the crank clockwise from the front. I believe it was a 27mm bolt.

As they say, assembly is the reverse. Lots of good tips in the comments for the 3 videos.

sam08861

ps... have 195K miles on it.