Intake Manifold Lower Section, With Fuel Rail

Intake Manifold Lower Section, with Fuel Rail

Special tools, testers and auxiliary items required

• Torque Wrench 5-50 Nm (V.A.G 1331)

• Ring Spanner Insert (V.A.G 1331/2)

• Hand Vacuum Pump (VAS 6213)

Removing

• The following removal and installation procedure is for the left lower section of the intake manifold. The procedure for the other side is identical.

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

• The fuel pressure must be reduced to residual pressure before opening the high pressure area of the fuel injection system. Refer to => [ Releasing Pressure in High Pressure Area ] Releasing Pressure In High Pressure Area.

- Reduce the 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 section and fuel rail.

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

The engine could be destroyed.

• 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, paying attention to the following:

• If a fuel injector was removed form the cylinder head, then the Teflon(R) seal must be replaced.

• Replace the seals and the O-rings.

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

Move the intake manifold flaps in direction of - arrow - when installing the intake manifold lower section.






- Connect (VAS 6213) to intake manifold runner control vacuum actuator, as shown in the illustration.






- Generate vacuum using hand vacuum pump.

• The intake flaps are opened.

• If the intake manifold flaps are not opened, they may get jammed when installing the intake manifold lower section on the cylinder head.

- Press the intake manifold lower section evenly on the fuel injectors.

- Tighten the bolts and nuts in a diagonal sequence on the intake manifold lower section according to the tightening specification.

• Intake manifold lower section tightening specification. Refer to => [ Tightening Specification, Intake Manifold Lower Section ] Lower Intake Manifold Section Overview.

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

- Connect the fuel pressure sensor connector - 4 -.






- Counter hold the threaded connection and tighten the union nut - 1 -.

• Tightening Specifications: Intake manifold lower section assembly overview, refer to => [ Lower Intake Manifold Section Overview ] Lower Intake Manifold Section Overview

- Make sure the high pressure line is free of tension.

- Install the supercharger.