Fuel Rail: Service and Repair

Lower Intake Manifold with Fuel Rail

Special tools, testers and auxiliary items required

• Ring Spanner Insert (V.A.G 1331/2)

• Hand Vacuum Pump (VAS 6213)

Removing

• The illustration shows removing and installing on cylinder bank 2 (left).

There is a risk of injury because the fuel is under very high pressure.

• Reduce the fuel pressure down to residual pressure before opening the high pressure area of the fuel injection system.

- Reduce fuel pressure in high pressure area. Refer to => [ Releasing Pressure in High Pressure Area ] Releasing Pressure In High Pressure Area.

- Remove the supercharger.






- Push the vacuum hoses to the side.






- Disconnect the fuel pressure sensor (G247) connector - 4 -.

- Remove the union nut - 1 - while counter holding the threaded connection.

- Remove the bolts and nuts - arrows - and remove the lower intake manifold and fuel rail.

- Disconnect the connector - 2 - on the intake manifold runner position sensor and remove the vacuum hose - 3 -.

Danger of causing damage to the engine.

• Cover the intake channels with a clean cloth to prevent small particles from getting into the engine through the intake channels in the cylinder heads.

Installing

Install in reverse order of removal. Note the following:

Tightening specifications:

• => [ Lower Intake Manifold, Fuel Rail and Fuel Injector Overview ] Service and Repair.

• => [ Tightening Specification, Lower Intake Manifold ] Service and Repair.

• Replace the seals and O-rings.

• Lubricate the fuel injector O-rings lightly with clean engine oil.








The intake manifold flaps could be damaged.

• To prevent the intake manifold flaps from jamming with the baffles in the cylinder head, the flaps must be open all the way in direction of - arrow - when installing the lower intake manifold.

- Connect the (VAS 6213) to the connection on the Intake Manifold Runner Control (IMRC) vacuum actuator, as illustrated.






- Produce a vacuum using the pump.

• The intake flaps are opened.

- Press the lower intake manifold with the fuel rail evenly onto fuel injectors.

- Tighten the bolts and nuts for the lower intake manifold. Refer to => [ Tightening Specification, Lower Intake Manifold ] Service and Repair.






- Remove the hand vacuum pump from the connection on the intake manifold runner control vacuum actuator.

- Install the high pressure line. Refer to => [ High Pressure Line ] Service and Repair.

- Install the supercharger.