Intake Manifold
Intake Manifold
Special tools, testers and auxiliary items required
• Socket Insert XZN 10 (T10385)
• Socket XZN 8 (T40159)
• Torque Wrench (5-5) Nm (V.A.G 1331)
• Hose Clip Pliers (VAS 6362)
• Ratchet, Reversible (V.A.G 1331/1)
• Engine Bung Set (VAS 6122)
• Follow the safety precautions when working on the diesel direct injection system. Refer to => [ Safety Precautions ] Diesel Fuel Injection.
• Observe the rules for cleanliness. Refer to => [ Clean Working Conditions ] Diesel Fuel Injection.
Always follow these instructions before and during work.
Removing
• Make sure no contaminants enter the fuel system when removing the intake manifold.
• Seal off the connections in the fuel system using the plugs from the engine bung set (VAS 6122).
- Remove the engine cover. Refer to => [ Engine Cover ] Engine Cover.
- Remove the protective strip, if equipped.
- Loosen the high pressure line or fuel line bolts - arrows - on the intake manifold.
- Disconnect the fuel injector - A - connectors, the exhaust pressure sensor 1 (G450) connector - B - and the fuel pressure sensor (G247) connector - C -.
- Remove the coolant line bolts - arrows - from the intake manifold and lay the line in front of the intake manifold.
- Unclip the wiring harness from the wiring guide for the glow plugs.
Always follow the procedure "glow plug connector, disconnecting and connecting".
- Disconnect the glow plug connectors. Refer to => [ Glow Plug Connectors, Disconnecting and Connecting ] Glow Plug Connectors, Disconnecting and Connecting.
- Remove the high pressure line between the high pressure fuel pump and fuel rail.
- Loosen the hose clip - arrow - using hose clip pliers (VAS 6362) and remove the line from the fuel rail.
- Before removing, clean the return line connection on the fuel injectors (for example using a commercially available detergent).
- Dry the return line connections.
- Cover the return line connections with a cloth.
- Remove the fuel return line connections from the fuel injectors. Pull them upward to release them - arrow -.
• Maintain clean working conditions. Dirt and contaminants must not enter the return lines and the connections on the fuel injectors.
- Loosen the hose clips using hose clip pliers (VAS 6362) and remove the fuel return line.
- Loosen the hose clip - 4 - using the hose clip pliers (VAS 6362) and remove the fuel return line from the high pressure fuel pump.
- Seal the lines so that the fuel system is not contaminated by dirt, etc.
- Remove the fuel return lines.
- Disconnect the EGR vacuum regulator solenoid valve (N18) connector - 1 - and the throttle valve control module (J338) connector - 3 -.
- Loosen the clamp - 4 - and remove the charge air hose.
- Remove the oil dipstick bracket - arrow -.
Make sure the connecting pipe decoupling element does not bend or stretch. Cracks could develop.
- Disconnect the connecting pipe - 2 -.
- Remove the intake manifold bolts using Socket XZN 8 (T40159) in a diagonal sequence working from the outside to the inside.
- Remove the intake manifold.
Installing
Install in reverse order of removal. When doing this note the following:
• Always replace seals.
• When installing the high pressure line or fuel lines, make sure no dirt or contaminants enter the fuel system.
• Only remove the sealing plugs right before installing the fuel lines.
• Do not change the angles of the high pressure lines
• Make sure lines connections are securely fastened.
• Do not swap supply and return lines.
- Tighten the intake manifold bolts in a diagonal sequence from inside to outside:
• Tightening specifications, see - item 2 - in => [ Intake Manifold and Attachments Overview ] Intake Manifold and Attachments Overview.
- Tighten the high pressure line union nuts by hand.
- Make sure the high pressure line is free of tension.
- Use torque wrench (5-50 Nm) (V.A.G 1331) with ratchet, reversible (V.A.G 1331/1) and socket (T40055) to tighten the high pressure line.
Tightening Specifications
• => [ Fuel Rail and Injectors Overview ] Service and Repair
• => [ Intake Manifold and Attachments Overview ] Intake Manifold and Attachments Overview
- Fill the fuel system. Refer to => [ Fuel System, Filling and Bleeding ] Fuel System, Filling and Bleeding.