Intake Manifold With Fuel Rail

Intake Manifold with Fuel Rail

If the fuel rail is removed or replaced, the Intake Manifold Runner Position (IMRC) 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)

• Multipoint Socket (T10347)

• Hazet Oil Filter Wrench (2171-1) or an Oil Filter Wrench (3417)

• Multipoint Socket (T10347)

Removing

- Remove engine cover.

• To access the fuel injectors, the intake manifold and the fuel rail with the IMRC valves must be removed.

• The combustion chamber seal (Teflon) 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 High Pressure Area ] Releasing Pressure In High Pressure Area.

- Disconnect the battery at the negative terminal.

- 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, disengage the clips to do so - arrows -.

- Remove both the lower air guide and the air guide hose.






- Disconnect the connector - 1 - from the Mass Airflow (MAF) sensor (G70).






- Open the hose clamp - 2 -.

- Remove the bolt - 4 - and the air filter housing with the air intake hose.

• Ignore - 3 -.

- Disconnect the vacuum line - arrow - to the Evaporative Emission (EVAP) canister.






- Disconnect the following electrical connectors.

1 Intake Air Temperature (IAT) sensor (G42)
2 Evaporative Emission (EVAP) canister purge regulator valve 1 (N80)
3 Throttle valve control module (J338)

Disconnect the connector - 1 - from the camshaft position sensor (G40).






- Remove the noise insulation by loosening the fasteners - 1 and 2 -.






- 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 -.






- Disconnect fuel supply hose - 2 - by pressing release ring.






• The fuel system must have no pressure.

• Use a clean rag to absorb exiting fuel.

- Open the spring clamp - upper arrow - and remove the fuel supply line from the high pressure pump.






- Open the high pressure fuel line union nut - lower arrow - 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 IMRC valve.






- Remove both coolant line bolts - arrows - from the intake manifold.






- Disconnect the electronic 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 with a (2171-1) or a (3417).






- Open the cable bracket - arrow - and free up the cable.






- Remove the intake manifold bolts using (T10347).

• The throttle valve control module (J338) 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 IMRC sensor and remove the intake manifold.






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

• Seal the intake channels with a clean cloth.

- Disconnect 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.

- Further installation is performed in reverse order.

• Tightening specifications, refer to => [ Intake Manifold Overview ] Intake Manifold Overview.

• Tightening specifications, refer to => [ Fuel Rail Overview ] Fuel Rail Overview