Intake Manifold with Fuel Rail
Intake Manifold with Fuel Rail
• If the intake manifold is replaced, the intake manifold runner position sensor (G336) must be adapted to the engine control module (J623). Refer to "Guided Functions" in the vehicle diagnostic tester.
Special tools, testers and auxiliary items required
• Oil Filter Wrench (3417)
• Socket TORX(R) T30 (T10347)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Assembly Tool (T10118)
=> [ Fuel Rail, Separating from the Intake Manifold ]
Removing
• To access the fuel injectors, the intake manifold and the fuel rail with intake manifold runner control valve must be removed.
• The combustion chamber seal (Teflon) and the O-ring must always be replaced.
• Intake manifold overview, refer to => [ Intake Manifold Overview ] Intake Manifold Overview.
• Fuel rail overview, refer to => [ Fuel Rail Overview ] Fuel Rail Overview.
- Read the safety precautions before starting. Refer to => [ Safety Precautions ] Fuel Supply.
- Pay attention to the rules of cleanliness. Refer to => [ Clean Working Conditions ] Fuel Supply.
The fuel system is under pressure!
• Before opening high pressure components of the fuel injection system, the fuel pressure must be relieved to residual pressure, refer to => [ High Side Fuel Pressure, Releasing ] Service and Repair.
- Remove the engine cover. Refer to => [ Engine Cover ] Engine Cover.
- Remove the charge air guide from the noise generator, if equipped.
- Clean the contact surface from the intake manifold to the cylinder head.
- Remove the air filter housing. Refer to => [ Air Filter Housing ] Air Filter Housing.
- Disconnect the vent line - arrow - from the Evaporative Emission (EVAP) canister and disconnect the electrical connector from the EVAP canister purge regulator valve 1 (N80).
- Disconnect the following electrical connectors as well:
1. Intake air temperature sensor (G42)
2. Throttle valve control module (J338)
- Disconnect the vacuum line - 1 - at the separating point - 2 - and remove the crankcase ventilation hose - 3 -.
- Remove the bolts - arrows - for the fuel supply line and lay the line to the side.
The fuel system must have no pressure. Refer to => [ High Side Fuel Pressure, Releasing ] Service and Repair.
- Loosen the high pressure fuel line union nut - lower arrow -.
- Disconnect the vacuum line - arrow - from the intake manifold runner control valve (N316).
- Remove the bolts - arrows - for the coolant line from the intake manifold.
- Use the assembly tool (T10118) to unlock the connector from the fuel pressure sensor (G247) - 1 -, and then disconnect the connector.
- Loosen the hose clamp - 2 -.
- Remove the bolt - 4 -.
- Disconnect electrical connector - arrow -.
- Remove the noise insulation.
- Disconnect the charge air hose by lifting the clamp - 1 - and loosening the hose clamp - 2 -.
- Seal off the connections on the charge air cooler with a clean cloth.
- Remove the bolt - 1 - and remove the charge air pipe downward.
- Disconnect the connectors - 1 though 3 - and remove the bracket from the intake manifold.
1. Camshaft position sensor (G40) connector
2. Knock sensor 1 (G61) connector
3. 8-pin harness connector for the fuel injectors
- Remove the throttle valve control module bolts - arrows -.
- Remove the intake manifold support by removing the nut - 1 - and bolt - 2 -.
- Remove the oil filter. Refer to => [ Oil Filter, Oil Cooler and Oil Pressure Switch Overview ] Service and Repair.
- Loosen the line bracket - arrows -.
- Loosen the line - arrow - from the intake manifold.
- Use the socket TORX(R) T30 (T10347) to remove the nuts - A - and loosen the bolts - arrows - from the intake manifold.
- Carefully pull the intake manifold and fuel rail away from the cylinder head just a little.
- Disconnect the electrical connector - arrow - from the intake manifold runner position sensor and remove the intake manifold.
- Cover the intake passages with clean cloths.
• The fuel injectors remain in the fuel rail.
- Fuel rail, separating from the intake manifold. Refer to => [ Fuel Rail, Separating from the Intake Manifold ].
Installing
Conditions:
• The fuel injectors sit inside the cylinder head. Install the fuel injectors. Refer to => [ Fuel Injector ] Fuel Injector.
- Mount the intake manifold onto the cylinder head on the stud bolts (lower left and right).
• Make sure the fuel injectors are installed correctly and pay attention to the wiring bracket when installing the intake manifold (located under the intake manifold).
- When installing the intake manifold, pull the manifold back out slightly and the fuel injectors will remain in the fuel rail, then remove the fuel injectors again from the fuel rail and insert the fuel injectors back into the cylinder head.
Install in reverse order of removal. When doing this note the following:
• When attaching the bracket onto the intake manifold, make sure it clips into both latches.
Tightening specifications:
• Intake manifold overview, refer to => [ Intake Manifold Overview ] Intake Manifold Overview.
• Fuel rail overview, refer to => [ Fuel Rail Overview ] Fuel Rail Overview.
Fuel Rail, Separating from the Intake Manifold
Conditions:
• The intake manifold must be removed. Refer to => [ Intake Manifold with Fuel Rail ] Intake Manifold with Fuel Rail.
Separating
- Remove the EVAP canister purge regulator valve 1 (N80) - arrow - from the bracket.
- Loosen the double check-valve - 1 - and the ventilation line - 2 -, if equipped.
- Open the hose clamp - 1 -.
- Remove both bolts - arrows - from the fuel rail.
- Disconnect the fuel rail from the intake manifold.
Installing
Install in reverse order of removal. When doing this note the following:
- Tighten the fuel line.
Tightening specifications:
• Fuel rail overview, refer to => [ Fuel Rail Overview ] Fuel Rail Overview.
- Install the intake manifold with the fuel rail. Refer to => [ Intake Manifold with Fuel Rail ] Intake Manifold with Fuel Rail.