Intake Manifold: Service and Repair

Intake Manifold

Special tools, testers and auxiliary items required

• Torque Wrench 5-50 Nm (V.A.G 1331)

• Ratchet (V.A.G 1331/1)

• Pliers (3314)

• Socket XZN 8 (T40159) for vehicles with an aluminum intake manifold

• Socket TORX T 30 (T10405) for vehicles with a plastic intake manifold

Removing


• Follow the guidelines for a clean working environment when working on the fuel system. Refer to => [ Fuel System ] Fuel System.

• Always follow these rules before and during work.

- Remove the engine cover. Refer to => [ Engine Cover ] Service and Repair.

- Remove the noise insulation from the cylinder head cover.

- Remove the noise insulation - 1 -.






- Remove the coolant hose by loosening the hose clamp - 2 -.






Removing the Air Guide Hoses and Couplings





- Release the retaining tab - A - on the connector coupling by pulling the securing clip - arrow -.

- Do not use tools to separate the air guide pipes and hoses.

- Remove the bolts - 1 and 3 -.






- Loosen the clamp - 5 - and remove the air guide pipe - 2 - in its installed position.

• Ignore - 4 -.

- Disconnect the connectors - 5 - from the glow plugs.






- Open the union nuts on the high pressure pump - 6 - and on the fuel rail - 1 - and remove the fuel high pressure line.

- Remove the bolts - arrows - on the brackets for the fuel high pressure line.

- Open the clamps - arrows - and free up the wiring harness.






- Remove the fuel return lines - 1, 2 and 3 -.






- Remove the bolts on the brackets and remove the return line.

- Remove the bolt - 4 -.

- Disconnect the connectors - 9 and 7 -.






- Remove the bolts - 6 - from the EGR connecting pipe.

Additional for Vehicles with a Plastic Intake Manifold:

- Remove the fuel rail. Refer to => [ Fuel Rail ] Service and Repair.

All Vehicles:

- Open the clamp - 8 - on the air guide hose and move it downward.






- Remove the bolt - 9 - from the oil dipstick bracket.

- Tighten the intake manifold bolts in a diagonal sequence starting from the outside and working in.

- Remove the intake manifold.

Installing

Installation is carried out in the reverse order while noting the following:

- Replace the seals

- Tighten the intake manifold bolts in a diagonal sequence starting from the outside and working in.

• Tightening specifications. refer to => [ (Item 2) Bolt ] Intake Manifold With Attachments Overview.

- Install the air guide pipe.

Install the Air Guide Hoses with the Coupling.





• Replace the sealing ring if it is damaged.

• Make sure the sealing ring sits completely in the groove all around the air guide pipe/hose.

• Coat the sealing surface and the sealing ring with silicone-free lubricant.

- Pull the securing clip into the release position - 1 -.

- Insert the air guide pipe/hose as far as the stop and press the securing clip into the locked position - 2 -.

- Press the air guide pipe/hose on and pull on it to make sure the connection is engaged correctly.

- Install the noise insulation.