Intake Manifold

Intake Manifold

Special tools, testers and auxiliary items required

• Multi-point socket (T10385)

• Multi-point socket (T40159)

• Torque Wrench (V.A.G 1331)

• Spring-type clip pliers (VAS 6362)

• Ratchet (V.A.G 1331/1)

• Engine bung set (VAS 6122)

CAUTION!
• Follow the safety precautions when working on the diesel direct injection system. Refer to --> [ Safety Precautions ] Safety Precautions.

• Observe rules for cleanliness. Refer to --> [ Clean Working Conditions ] Clean Working Conditions.

Always follow these instructions before and during work.

Removing

• Make sure no contaminants enter the fuel system when removing the intake manifold.

• Seal the fuel system connections with sealing plugs from the engine bung set (VAS 6122).

- Remove engine cover. Refer to --> [ Engine Cover ] Engine Cover.

- Remove protective strip --> [ 1 Protective Strip ] Removal and Replacement.

- Loosen high pressure line or fuel lines - arrows - on the intake manifold.





- Remove connector on the fuel injectors - A -, the exhaust pressure sensor 1 - B - and the fuel pressure sensor - C -.





- Remove coolant line bolts - arrows - from the intake manifold and lay the line in front of the intake manifold.

- Unclip wiring harness from the wiring guide for the glow plugs.

CAUTION!
Always follow the procedure "Glow Plug Connectors, Disconnecting and Installing".

- Remove the glow plug connectors. Refer to --> [ Glow Plug Connectors ] Glow Plug Connectors.

- Remove the high pressure line --> [ 21 High Pressure Lines, 25 Nm ] Removal and Replacement between the high pressure fuel pump and rail element (high pressure reservoir).

- Loosen the hose clip - arrow - with hose clip pliers (VAS 6362) and remove the line on the rail element (high pressure reservoir).





- Before removing, clean the return line connection on the fuel injectors (use a commercially available detergent).

- Dry the return line connections.

- Cover the return line connections with a rag.

- Remove the fuel return line connections on the fuel injectors. Pull upward to release them - arrow -.





• Maintain clean working conditions. Dirt and contaminants must not enter the return lines and the connections on the fuel injectors.

- Loosen the hose clips with the hose clip pliers (VAS 6362) and remove the fuel return line --> [ 4 Fuel Return Line ] Removal and Replacement.

- Loosen hose clip - 4 - with the hose clip pliers (VAS 6362) and remove the fuel return line at the high pressure fuel pump.





- Seal lines so that the fuel system is not contaminated by dirt etc.

- Remove fuel return lines --> [ 2 Fuel Return Lines ] Removal and Replacement.

- Disconnect connector from the EGR vacuum regulator solenoid valve - 1 - and the throttle valve control module - 3 -.





- Loosen clamp - 4 - and remove charge air hose.

- Remove oil dipstick bracket - arrow -.

CAUTION!
Make sure the connecting pipe decoupling element does not bend or stretch. Cracks could develop.

- Disconnect connecting pipe - 2 -.

- Remove intake manifold bolts with a socket (T40159) in a diagonal sequence working from the outside to the inside.

- Remove intake manifold.

Installing

Install in reverse order of removal noting the following:

• Always replace seals.

• When installing the high pressure line or fuel lines, make sure no dirt or contaminants enter the fuel system.

• Only remove sealing plugs right before installing the fuel lines.

• Do not change the angles of the high pressure lines

• Make sure lines connections are securely fastened.

• Do not swap supply and return lines.

- Tighten intake manifold bolts in a diagonal sequence from inside to outside:

• Tightening specifications, refer to --> [ 2 8 Nm ] Intake Manifold With Attachments Assembly Overview.

- Tighten high pressure line union nuts by hand.

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

- Use torque wrench (V.A.G 1331) with the ratchet (V.A.G 1331/1) and socket (T40055) to tighten high pressure line.





Tightening specifications

• --> [ Fuel System Assembly Overview ] Removal and Replacement

• --> [ Intake Manifold with Attachments Assembly Overview ] Intake Manifold With Attachments Assembly Overview

- Fill the fuel system. Refer to --> [ Fuel System, Filling ] Fuel System, Filling.