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    Thread: DIY: MKIV AEG Intake Manifold on MKIII 2.0L ABA OBDII

    1. Member duke_seb's Avatar
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      03-27-2006 07:29 PM #1



      Parts Needed for swap
      1 MKIV AEG Upper and Lower Intake Manifold
      1 MKIV AEG Valve Cover (MKIII one is too tall)
      1 Head to Plenum Gasket
      1 Middle Plenum Gasket
      1 Throttle Body Gasket
      1 Valve Cover Gasket
      -10 feet of wire (not sure the gauge but you need it for the IAT and the MAF so whatever that is I just used what i could find that look the same)
      -4 Injector Replacement Kits (Comes with 3 O-Rings, 1 Injector Cap per kit)
      -1 Foot of 1/8" Vacuum Hose (Autozone or Canadian Tire)
      -5 Bolts for connecting the 2 pieces of the intake together (you may find most or all being used for odd things on the MKIII or MKIV manifold make sure you have them.....
      -Plug (I used a cap from a Caulking tube .....temp until i find something better)

      -051 103 211A - Part Number for Hose that connect the Crankcase to the valve cover to the intake pipe (about 20 bucks at the dealer)

      or

      -1 Universal Breather Filter, 1 Foot of 3/4" Heater Hose (Canadian Tire or Autozone)

      Tools Needed for Job
      -Rachet Set
      -19mm wrench or 19mm deep socket to take off the IAT from the old manifold
      -Drill and bits
      -Metric Tap and Die set or JB WELD (i used this....couldnt find a tap set)
      -Allen Keys
      -Hex Keys (May not need I needed one to get the last bolt out of the Throttle Body)
      -Xacto Knife
      -Needle Nose Pliers
      -Robertson (Black), Phillips (small star), Flat Head
      -Clamping Pliers
      -couple of goodsize books (or something that will hold up the gas pedal)


      OK....Now the Install
      -Disconnect the Battery
      -put books under the gas pedal
      -Take the Intake Piping out (Unplug all wiring MAF..etc.)
      -Take out upper intake plenum
      -Disconnect the plugs from the Injectors
      -Take off the Metal Clips that hold the Injectors to the Fuel Rail (Save youll Need these)
      -Remove Fuel Rail (WARNING! You will spill gas!)
      -Pull all the injectors out of the Head (I waited until after i took the lower piece off and i found it to be a pain prolly easier if its still on there)
      -Take off the Lower part of the Manifold and put on a new gasket and put the new lower manifold on
      -Take the Injectors and put the caps off (may be difficult - I used Needle Nose to pull then off)
      - Replace the Injector 2 Rubber O-Rings and the 1 Plastic O-Ring with 3 Rubber O-Rings
      - Replace the Caps with new ones in the kit (after putting on make sure you hear the click)
      - Push Injectors back into the Lower Manifold Piece
      - Put Fuel Rail back on
      - Put Clips back on
      - Take Throttle Body off old Intake get some Paper towel and clean out the inside of it
      - Turn TB upsidedown and put it on the MKIV Manifold
      - Now take the IAT out of the side of the Old Mani and find the right size bit and drill into the back of the manifold then tap the hole out ( I used an oversized bit and then JB Welded the IAT in place because i couldnt find a kit and i wasnt spending 40 bucks on one.....)
      - Take off the MKIII Valve Cover and PCV and replace the Valve Cover Gasket
      - Put in the MKIV AEG Valve Cover
      - Install MKIV PCV Assembly
      - Put Gasket and Upper Manifold on
      - Extend IAT is on the same line as the plugs for the injectors (cut 2 - 1 foot pieces of wire)
      - Plug injectors back in
      - If using JB Weld for the IAT do not plug back in until a little later to let it dry a little first
      - Extend MAF Wiring (Cut 4 - 2 foot Pieces) route inbetween the manifolds
      - Connect the FPR to the intake manifold with the foot long piece of 1/8" vacuum tube
      - Connect the Vacuum Line Coming from the EVAP Purge Regulator to its spot that you took it out of on the Throttle Body

      - Connect the Vacuum line that Comes from the TB and goes to the side of the Intake

      - Twist the Plastic Hose Coming up from the Crankcase and put the 3/4 Piece of Heater Hose and connect it to the intake (or Use the factory piece that i gave a part number for above)
      - if you dont use the factory piece then put a breather filter on the PCV (not in picture got it after i took the picture)
      -Plug off the Vacuum i used a cap from MONO Caulking (lack of better thing at the time)
      -Plug in IAT
      -Plug Battery In
      - Play around until you get the throttle cable right......then take the books out (I did it with the car running so that I could get the right idle

      RE-ADAPT YOUR IDLE - Steps without a VAG-COM
      -Disconnect the Battery for 3 minutes
      -After the Battery is plugged back in turn your key to the on Position for 3 minutes
      -Start Car let Idle for 3 minutes
      -Drive out of your spot rev the car over 5000 in second then pull over and turn car off
      -Start Car and your all done

      - put cover on if you have one.....your done....Drink

      Any Questions Feel Free to IM me

      If anyone has any pictures of the Secondary Air Pump I would like to see how that would connect with everything ..... a couple shots of the engine bay would be nice


      Modified by duke_seb at 6:58 PM 3-28-2006

      :bow Old Vortex

      Quote Originally Posted by zukiphile View Post
      Really Volvo? A failure of system that is supposed to save the inattentive would have been noticed by a real inattentive driver?
      Really?

    2. Member 96jettasexer's Avatar
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      03-27-2006 07:34 PM #2
      excellent work
      Franco

    3. Member TRLSTYLE's Avatar
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      03-27-2006 07:36 PM #3
      that should help anyone who will be boosting an ABA and running a front mount some too.

    4. 03-27-2006 07:36 PM #4
      Any performance gains noticed from this, or just for looks?

    5. Member duke_seb's Avatar
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      03-27-2006 07:39 PM #5
      I noticed a bunch......but i think now that ive done it that my Throttle Cable was a little loose before but with cam chip intake and AEG exhaust mani the car seems to go balls to the wall
      :bow Old Vortex

      Quote Originally Posted by zukiphile View Post
      Really Volvo? A failure of system that is supposed to save the inattentive would have been noticed by a real inattentive driver?
      Really?

    6. Member duke_seb's Avatar
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      03-28-2006 05:48 PM #6
      bump for toonie tuesday... in canada of course.....

      for all you americans a toonie is a canadian two dollar coin

      :bow Old Vortex

      Quote Originally Posted by zukiphile View Post
      Really Volvo? A failure of system that is supposed to save the inattentive would have been noticed by a real inattentive driver?
      Really?

    7. 03-28-2006 05:54 PM #7
      Quote, originally posted by duke_seb »
      bump for toonie tuesday... in canada of course.....

      for all you americans a toonie is a canadian two dollar coin

      You wacky America "Lite" and your sayings.

      Looks good duke, someone should do a before and after dyno on this to see if any power comes from it.


    8. Member duke_seb's Avatar
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      03-28-2006 05:59 PM #8
      I plan to do an after i do notice a real difference in the top end.....

      Im hoping when i get my lighten flywheel in that I will notice some more low end

      :bow Old Vortex

      Quote Originally Posted by zukiphile View Post
      Really Volvo? A failure of system that is supposed to save the inattentive would have been noticed by a real inattentive driver?
      Really?

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      03-28-2006 06:10 PM #9
      nice work man

      take the protective blue film off the vw logo on the manifold cover....


    10. Member duke_seb's Avatar
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      03-28-2006 06:13 PM #10
      Quote, originally posted by n0rdicalex »

      take the protective blue film off the vw logo on the manifold cover....

      i have to look it didnt look like there was any film there

      :bow Old Vortex

      Quote Originally Posted by zukiphile View Post
      Really Volvo? A failure of system that is supposed to save the inattentive would have been noticed by a real inattentive driver?
      Really?

    11. Member veedub8422's Avatar
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      03-28-2006 06:19 PM #11
      looks great. sweet idea. anyone gonna try this with a mkIV vr6?

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      03-28-2006 06:22 PM #12
      sweet write up man

      are you gonna keep the plastic cover on there?

      it looks better without it


    13. Member duke_seb's Avatar
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      03-28-2006 06:43 PM #13
      the plastic cover was 50% of the reason i did the swap...lol
      :bow Old Vortex

      Quote Originally Posted by zukiphile View Post
      Really Volvo? A failure of system that is supposed to save the inattentive would have been noticed by a real inattentive driver?
      Really?

    14. Member Violetburning's Avatar
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      08-14-2008 09:13 AM #14
      can you use the MKIII throttle body?

    15. Moderator root beer's Avatar
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      08-14-2008 09:19 AM #15
      This looks like it's SO not worth the effort. And this is coming from a guy who does some pretty asinine ****.
      How to build a relatively inexpensive, reliable, powerful VR6
      I am ready, I am

      I want to buy some 4x100 15" Pininfarinas. If you have one of the few sets i've seen, please let me know.

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      08-14-2008 09:21 AM #16
      Quote, originally posted by Violetburning »
      can you use the MKIII throttle body?

      tb is the same


    17. Senior Member Dan J Reed's Avatar
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      08-14-2008 10:04 AM #17
      Quote, originally posted by root beer »
      This looks like it's SO not worth the effort. And this is coming from a guy who does some pretty asinine ****.

      Yup, jacked his car up with rock he did.


    18. Member [7one8]VDub's Avatar
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      08-14-2008 06:21 PM #18
      ^^^ true story

    19. 08-14-2008 07:15 PM #19
      dam clean that bay.

    20. Member duke_seb's Avatar
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      04-07-2009 04:16 PM #20
      im parting out my ride..... if anyone wants all the parts for the swap let me know i can mail them out

      :bow Old Vortex

      Quote Originally Posted by zukiphile View Post
      Really Volvo? A failure of system that is supposed to save the inattentive would have been noticed by a real inattentive driver?
      Really?

    21. Member Suter's Avatar
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      04-07-2009 05:15 PM #21
      Quote, originally posted by duke_seb »
      im parting out my ride..... if anyone wants all the parts for the swap let me know i can mail them out

      Have the plastic cover?


    22. Member duke_seb's Avatar
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      04-07-2009 05:21 PM #22
      sorry gone
      :bow Old Vortex

      Quote Originally Posted by zukiphile View Post
      Really Volvo? A failure of system that is supposed to save the inattentive would have been noticed by a real inattentive driver?
      Really?

    23. 04-06-2010 08:38 PM #23
      Nice write up, I'm gonna try this

    24. Member whtgolf2.0's Avatar
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      04-06-2010 10:05 PM #24
      I did this a while ago and my only suggestion is double up the injector o-rings, I didn't and had a bad leak there.
      Heres my end result:

      I was in the middle of flushing the coolant, so I realize the bottle is empty and the cap is off.

    25. Member sk8too's Avatar
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      04-06-2010 10:09 PM #25
      it is just me or do the provided pic's not work?
      97 Jetta GL, OBDI VR swapped, 262 cams, GIAC chip, turn 2 style CAI, Magnaflow catback, 2.9 clone manifold, eurospec flywheel, B&G RS2 coilovers, MKIV front and rear seats

    26. Member goneeuro's Avatar
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      04-06-2010 10:29 PM #26
      What top intake box is that on whtgolfs set up.

    27. Member csrgti's Avatar
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      04-06-2010 10:34 PM #27
      Quote, originally posted by sk8too »
      it is just me or do the provided pic's not work?

      X2


    28. Member whtgolf2.0's Avatar
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      04-06-2010 10:37 PM #28
      It is the stock one. I used a hole saw and cut out a section for the maf to fit into, then made a cover plate for the old hole.





      Modified by whtgolf2.0 at 7:51 PM 4-6-2010


    29. Member sk8too's Avatar
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      04-06-2010 11:02 PM #29
      so probly a dumb question, but i'm getting ready to order a kinetic turbo kit stage 2 for my 2.0L so if i were to do the AEG intake swap, would i need to order a different turbo kit? like the MKIV turbo kit?
      97 Jetta GL, OBDI VR swapped, 262 cams, GIAC chip, turn 2 style CAI, Magnaflow catback, 2.9 clone manifold, eurospec flywheel, B&G RS2 coilovers, MKIV front and rear seats

    30. Member pirate golf's Avatar
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      04-07-2010 12:23 PM #30
      Quote, originally posted by sk8too »
      it is just me or do the provided pic's not work?

      The pics from the original post? Probably has something to do with the age of the thread.


    31. Member Oricalcos123's Avatar
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      04-07-2010 02:18 PM #31
      what is your car is an OBD 2 car and you still have an isv, take it that this wont work

    32. Member sin bar's Avatar
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      04-07-2010 03:21 PM #32
      duke_seb with a diy?

      how'd i miss that one four years ago?


    33. Member Louie Bricants's Avatar
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      04-07-2010 03:28 PM #33
      Quote, originally posted by duke_seb »
      im parting out my ride..... if anyone wants all the parts for the swap let me know i can mail them out

      Can you cut everything into tiny pieces and ship it to me in an 8x10 box

      planetcaravan

    34. Member erict666's Avatar
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      04-21-2010 07:04 PM #34
      Quote, originally posted by whtgolf2.0 »
      I did this a while ago and my only suggestion is double up the injector o-rings, I didn't and had a bad leak there.
      Heres my end result:

      I was in the middle of flushing the coolant, so I realize the bottle is empty and the cap is off.

      what did you do for the intake tubing?

      Is it custom made?


    35. Member
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      09-24-2010 09:54 PM #35
      so im trying to understand this.i use my mk3 fuel injectors or do i use the mk4 aeg ones?thanks

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