Intake Manifold With Fuel Rail
Intake Manifold with Fuel Rail
If the fuel rail is removed or replaced, the intake manifold runner position sensor (G336) must be adapted to the Engine Control Module (ECM) (J623). Use a vehicle diagnosis tester.
Special tools, testers and auxiliary items required
• Assembly Tool (T10118)
• Hose Clip Pliers (V.A.G 1921)
• Socket Torx(R) T30 (T10347)
• Oil Filter Wrench (3417)
Removing
- Remove the engine cover.
• The combustion chamber seal (Teflon(R)) and the O-ring must always be replaced.
• Intake manifold assembly overview, refer to => [ Intake Manifold Overview ] Intake Manifold Overview.
• Fuel rail assembly overview, refer to => [ Fuel Rail Overview ] Fuel Rail Overview.
Fuel system is under pressure! Fuel pressure must be reduced to a residual pressure before opening high pressure area of injection system. Refer to => [ Releasing Pressure in the High Pressure Area ] Releasing Pressure In the High Pressure Area.
- Disconnect the battery Ground (GND) cable.
- Clean the contact surface from the intake manifold to the cylinder head.
- Remove the air duct cover by disengaging the slide clips - arrows -.
- Unclip the lower air guide, to do this disengage the clips - arrows -.
- Remove both the lower air guide and the air guide hose.
- Disconnect the vacuum line - arrow - to the Evaporative Emission (EVAP) canister.
- Disconnect the following electrical connectors.
1 Intake Air Temperature (IAT) sensor (G42)
2 EVAP canister purge regulator valve 1 (N80)
3 Throttle valve control module (J338)
Disconnect the connector - 1 - from the Camshaft Position (CMP) sensor (G40).
- Remove the noise insulation.
- Open the air guide pipe hose clamps - 2 -.
- Disconnect electrical harness connector - arrow -.
- Remove the bolts - 1 and 4 - and remove the air guide hose downward from the throttle valve control module.
- Remove the air guide hose.
- Disconnect the vacuum line - 1 - at the separating point - 2 - and remove the crankcase ventilation hose - 3 -.
- Unclip the fuel supply hose from the intake manifold.
• The fuel system must have no pressure.
• Use a clean cloth to absorb exiting fuel.
- Open the spring clamp - 1 - and remove the fuel supply line from the high pressure pump.
- Open the fuel high pressure line union nut - 2 - on the high pressure pump.
• Seal the open connections with clean caps and make sure no dirt has entered the fuel system.
- Remove the vacuum line - arrow - from the Intake Manifold Runner Control (IMRC) valve (N316).
- Remove both coolant line bolts - arrows - from the intake manifold.
• The Manifold Absolute Pressure (MAP) sensor (G71) connector must also be disconnected on vehicles with engine code CETA.
- Disconnect the connector from the fuel pressure sensor (G247) - 1 -.
- Disconnect the connectors - 1 and 3 - and remove the connector sideways from the retainer.
- Loosen the mounting nut - 1 - slightly and remove the bolt - 2 - completely.
- Remove the oil filter - arrow - using the (3417).
- Open the cable bracket - arrow - and free up the cable.
- Remove the intake manifold bolts using (T10347).
• The throttle valve control module must be removed in order to remove any bolts that are not accessible and not using the (T10347).
- Carefully pull the intake manifold with fuel rail away from the cylinder head slightly.
- Disconnect the connector - 1 - from the intake manifold runner position sensor and remove the intake manifold.
• The fuel injectors could remain stuck in the fuel rail.
• Seal the intake channels with a clean cloth.
- Separate the intake manifold from the fuel rail. Refer to => [ Fuel Rail ] Fuel Rail.
Installing
- Mount the intake manifold onto the cylinder head on the stud bolts (lower left and right).
• Make sure the fuel injectors are installed correctly.
- Install in reverse order of removal.
• Tightening specifications: Intake manifold assembly overview, refer to => [ Intake Manifold Overview ] Intake Manifold Overview
• Tightening specifications: Fuel rail assembly overview, refer to => [ Fuel Rail Overview ] Fuel Rail Overview