Intake Manifold With Fuel Rail

Intake Manifold with Fuel Rail

The intake manifold runner position sensor (G336) must be adapted to the engine control module (J623) after removing or replacing the fuel rail vehicle diagnosis, testing and information system (VAS 5052) "Guided Function".

• To access the fuel injectors, the intake manifold and the fuel rail with intake manifold runner control valve must be removed. (Depending on version, more or fewer work steps may be required).

• The combustion chamber seal (Teflon) and the O-ring must always be replaced.

• Intake manifold. Refer to => [ Intake Manifold Assembly Overview ] Intake Manifold Assembly Overview.

• Fuel Rail. Refer to => [ Fuel Rail Assembly Overview ] Fuel Rail Assembly Overview.

Removing

- Remove engine cover.

Fuel system is under pressure! Fuel pressure must be reduced to a residual pressure before opening high pressure area of injection system. Refer to => [ Before Opening High Pressure Fuel Injection System ] Service and Repair.

- Disconnect all electrical harness connectors necessary.

- Disconnect vacuum hose between intake manifold and vacuum pump from intake manifold.

• This vacuum hose and the vacuum pump (attached to rear of cylinder head) are only installed on vehicles with automatic transmission.

• Disregard items 1 and 2 in the illustration.

- Disconnect hose connections - arrows - from valve cover.

- Disconnect vacuum line - 2 - to EVAP canister.





- Disconnect fuel supply line - arrow -.





• The fuel system must have no pressure.

- Open both fuel lines - 2 and 3 - to high pressure pump.





- Remove bolt and nut - arrows -, then push the right front coolant pipe to the side with the coolant hoses still connected.





- Remove nit - arrow - for the oil dipstick guide tube.





This step only for engine code CDMA

- Disconnect electrical connector - 3 -.





- Remove bolt - arrow -.

- Remove hose - 2 -.

- Loosen hose clamp - 1 - and lay the air guide pipe Turbocharger Recirculating Valve (N249) to the side with the hose - 4 - still connected.

All engine codes

- Loosen hose clamp - 2 - and remove the air guide pipe from the throttle valve control module (J338).





• Ignore items - 1, 3 and 4 -.

- Disconnect connector - 1 - on the intake air temperature sensor (G42).





• Disregard - arrow -.

- Disconnect electrical connectors:





2 For injector valves, remove the connectors from the bracket
3 For evaporative emission (EVAP) canister purge regulator valve (N80)
4 Intake Flap Motor (V157)
5 Fuel pressure sensor (G247) and Camshaft Position (CMP) Sensor (G40), remove the connectors from the bracket

- Disconnect electrical connector - 1 -.





- Remove bolts - arrows - and remove Throttle Valve Control Module (J338).

- Remove nut - 2 - and bolt - 1 - and remove intake manifold support.





- Disconnect electrical connector - 1 - from Fuel Pressure Sensor (G247).





- Remove all bolts from intake manifold.

- Carefully pull off intake manifold with fuel rail from cylinder head.

• The fuel injectors could remain stuck in the fuel rail.

- Fuel rail, removing and installing. Refer to => [ Fuel Rail ] Fuel Rail.

Installing

- Installation is in reverse order of removal.

• Tightening Specifications, Intake Manifold. Refer to => [ Intake Manifold Assembly Overview ] Intake Manifold Assembly Overview.

• Tightening specifications, Fuel rail. Refer to => [ Fuel Rail Assembly Overview ] Fuel Rail Assembly Overview.