Question about 1983 Volkswagen Rabbit Pickup

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Engine heater? have an 82' 1.6D and wanted to know if I need to take the exhaust and intake manifolds off to do the job?? thanks

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You do not need to remove the manifolds to replace the frost plug heater.

If you are putting one in for the first time, it can be tricky to get the frost plug out.

If you are just replacing the unit, it is not too hard to get at. It is hard to see what you are doing as it is up kind of high.

It sometimes may even help to remove the front and transmission mount so that the engine can swing out of the way a little. It only takes a couple of minutes and can make access a little easier.

Posted on Apr 15, 2009

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If you haven't purchased one yet I would look into a heater that installs in the lower radiator hose. much easier, especially if the plug accidentally starts to leak.

Posted on Jan 11, 2009


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Exhaust smell coming thru vent 2008 avenger 2.4 goes away when I put it on recirculat

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Exaust intake leaking

It's exhaust manifold. There are two manifolds, the intake manifold in the valley between the cylinder heads, and the exhaust manifolds, one on each side of a v figured engine.

And, yes, a leak in the exhaust or the intake will make it run lean. If the leak is close to the engine, it can do harm to the valves, too. There is a gasket between the exhaust manifold and the engine block. Likewise, there is an intake manifold gasket between the intake manifold and the block.

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What part of the exhaust do you want to replace? If it is the exhaust manifold gasket, usually you don't need to touch intake, but it can be one of the most frustrating jobs if you haven't got the right tools. The right tools can twist and turn in the right places. If you haven't got the right tools , it can be easier to take both manifolds off to do job properly. More time to take intake manifold off , but less time in long run as you can access manifold/head surfaces if you haven't got right tools.

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I have been slowly losing coolant for several years. Only recently I can smell coolant when fan runs. Does a heater core have typical trouble spots? What are the basic procedures for RR an intake...

first check the radiator tanks, common problem with the plastic tanks getting a crack in them and then gets larger overtime. the intake manifold is also a common problem. look for coolant leaks in front of the engine and along the valve covers.replacing the intake gaskets is a rather big job(4 to 6 hours for an experienced mechanic)and the heater core is even a bigger task. the dash has to be removed to access the heater core. if you want step by step instuctions, you may want to puchase a HAYNES or CHILTON manual.

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My starter gave out yesterday. I didnt know it was inside the intake manifold. Either way i started the job last night, i am having a hard time pulling out the manifold. I already loosened the clamp but i...

These are the steps to follow to remove the Starter Motor and the Intake Manifold. If you follow them you'll have no problems when the job is done. Pay special attention to the pre-installation steps for the Intake Manifold.

To Replace the Starter, Remove or disconnect the following:
  1. Negative battery cable
  2. Intake manifold
  3. Starter electrical connectors
  4. Starter motor
View of starter motor removal and wires

To install, Install or connect the following:
  1. -S- terminal wire. Torque the nut to 35 inch lbs. (4 Nm).
  2. Starter electrical connectors. Torque the nut to 89 inch lbs. (10 Nm).
  3. Starter motor
  4. Mounting bolts. Torque the bolts to 22 ft. lbs. (30 Nm).
  5. Intake manifold
  6. Negative battery cable

  • Relieve the fuel system pressure
  • Drain the cooling system.

Remove or disconnect the following:
  1. Negative battery cable
  2. Intake manifold heat shield
  3. Sight shield
  4. Coil module connectors from the coil modules located on the valve covers
  5. Positive Crankcase Ventilation (PCV) hose and valve from the valve cover
  6. Fuel regulator vacuum tube
  7. Vacuum tubes from the AIR solenoid
  8. Fuel inlet and return lines
  9. Fuel rail bracket retaining nut at the rear lift bracket
  10. 2 pushnuts attaching the engine coolant heater wire and set it aside, if equipped
  11. Fuel injector electrical connections
  12. Fuel rail and injectors
  13. Plenum duct clamp at the rear of the intake manifold, loosen Intake manifold bolts and the manifold
  14. Clean the manifold mating surfaces.
Intake manifold torque sequence- 4.6L engines


  • Grease the inside edge of the rubber plenum duct.
  • Position the intake manifold by performing the following sub-steps:
  • Place the rear of the intake manifold into the plenum duct.
  • Place the front of the intake manifold downward on to the cylinder heads.
  • Install the intake manifold bolts and torque to 89 inch lbs. (10 Nm) in the sequence illustrated. DO NOT torque the intake manifold bolts when the engine is HOT or at operating temperature.
  • Make sure the plenum duct is fully attached to the rear of the intake manifold and tighten the plenum duct clamp to 20 inch lbs. (2.25 Nm).

Install or connect the following:
  1. Fuel rail and injectors and tighten the rail retainers to 89 inch lbs. (10 Nm)
  2. Fuel injector electrical connections
  3. Alternator coolant pipe/surge tank pipe and position onto the fuel rail studs
  4. Engine coolant heater wire onto the studs and install the pushnuts, if equipped
  5. Fuel rail bracket retaining nut at the rear lift bracket and tighten to 89 inch lbs. (10 Nm)
  6. Fuel inlet and return lines
  7. Vacuum tubes to the AIR solenoid
  8. Fuel regulator vacuum tube
  9. Positive Crankcase Ventilation (PCV) valve and hose to the valve cover
  10. Coil module connectors to the coil modules located on the valve covers
  11. Sight shield
  12. Intake manifold heat shield
  13. Negative battery cable
  14. Fill and bleed the cooling system.
Good Luck!! A HELPFUL - 4 THUMBS - rating for this solution would be greatly appreciated. Thank you for using FixYa.

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Head should be checked for warping and cracks. Follow torque instructions carefully when reinstalling the head.

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2000 Dodge Grand Caravan 3.3L Engine. few months ago I had coolant boiling over my surge tank. Initially the radiator cap lost its proper pressure capability but it wasn't the case but notice radiator had...

You can purchase an intake manifold gasket set from a local parts store. It should have the upper and lower intake gaskets contained in it. I see you plan on doing the valve cover gaskets as well. It might be a good idea to replace the plugs and wires at the same time to save some trouble down the road. I would recommend doing the oil change and change the thermostat at the same time as well.

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Intake manifold gasket

prev.gif next.gif Intake Manifold REMOVAL & INSTALLATION 1.9L SOHC Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Properly relieve the fuel system pressure.
  3. Drain the coolant system.
  4. Remove or disconnect the following:
    • Negative battery cable
    • Air cleaner fresh air hose
    • Positive Crankcase Ventilation (PCV) valve hose
    • Fuel line from the rail
    • Throttle cable from the throttle body
    • Throttle cable bracket nuts
    • Fuel injector electrical connectors
    • Throttle Position (TP) sensor electrical connectors
    • Idle Air Control (IAC) valve electrical connectors
    • Manifold Absolute Pressure (MAP) sensor electrical connectors
    • Exhaust Gas Recirculation (EGR) valve electrical connectors
    • Heater hose from the intake manifold outlet
  5. Position the wiring harness over the brake master cylinder
  6. Remove or disconnect the following:
    • Intake manifold support bracket bolt
    • Label the vacuum line for proper assembly
    • Drive belt
    • Power steering pump
    • Upper intake manifold bolts
    • Evaporative Emissions (EVAP) canister purge valve solenoid vacuum hose
    • Brake booster vacuum hose
    • Lower intake manifold bolts
    • Intake manifold
    To install:
  7. Thoroughly clean all gasket mating surfaces. Be careful not to damage or score the aluminum surface. If replaced, use Loctite® 290, to seal the new PCV valve inlet tube into the manifold. NOTE: Refer to Section 1 of this manual for the intake manifold torque sequence illustration. The illustration is located after the Torque Specification Chart.
  8. Install or connect the following:
    • New gasket and manifold. Torque the nuts in sequence to 22 ft. lbs. (30 Nm).
    • Power steering pump. Torque the fasteners to 27 ft. lbs. (38 Nm).
    • Drive belt.
    • Heater hose and install the manifold support bracket bolt. Tighten the bolt to 22 ft. lbs. (30 Nm).
    • Lubricate the male ends of the fuel lines with a few drops of clean engine oil, then connect the fuel supply and return lines.
    • Fuel line(s) in the retaining bracket. Torque the mounting screw to 36 inch lbs. (4 Nm).
    • Throttle cable to the throttle body and attach the accelerator cable bracket. Torque the bolts to 22 ft. lbs. (30 Nm).
    • Reposition the wiring harness and connect the wiring and vacuum hoses to their original locations. The harness leads to the TP sensor and EGR solenoid must be routed between the intake manifold runners.
    • Negative battery cable
  9. Fill the coolant system.
  10. Prime the fuel system by cycling the ignition ON for 5 seconds and OFF for 10 seconds a few times without cranking the engine.
  11. Start the engine, check for leaks, and repair if necessary.

Mar 27, 2009 | 2000 Saturn SL

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