Intake Manifold With Fuel Rail

Intake Manifold with Fuel Rail

Special tools, testers and auxiliary items required

• Oil filter wrench (3417)

• Multi point socket (T10347)

• Torque wrench 5-50 Nm (VAG 1331)

• Assembly Tool (T10118)

• If the intake manifold is to be replaced, the intake manifold runner position sensor must be adapted to the Engine Control Module (ECM).

Removing

• To access the fuel injectors, the intake manifold and the fuel rail with intake manifold runner control valve must be removed.

• The combustion chamber seal (Teflon) and the O-ring must always be replaced.

• Intake manifold assembly overview. Refer to --> [ Intake Manifold Assembly Overview ] Intake Manifold Assembly Overview.

• Fuel rail assembly overview. Refer to --> [ Fuel Rail Assembly Overview ] Fuel Rail Assembly Overview.

- Read safety precautions before beginning work. Refer to --> [ Safety Precautions ] Safety Precautions.

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

CAUTION!
Fuel system is under pressure! Before opening high pressure components of the fuel injection system, the fuel pressure must be relieved to residual pressure, procedures. Refer to --> [ High Side Fuel Pressure Releasing ] High Side Fuel Pressure Releasing.

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

- Remove the charge air pipe to the noise generator. Refer to --> [ Charge Air Pipe to Noise Generator ] Service and Repair.

- Clean the contact surface from the intake manifold to the cylinder head.

- Remove the air filter. Refer to --> [ Air Filter ] Air Filter.

- Disconnect the vent line - arrow - from the Evaporative Emission (EVAP) canister and disconnect the electrical connector on the EVAP canister purge regulator valve.





- Disconnect the following electrical connectors as well:

1. Intake Air Temperature (IAT) sensor

2. Throttle valve control module

- Disconnect the vacuum line - 1 - at the separating point - 2 - and remove the crankcase ventilation hose - 3 -.





- Remove the bolts - arrows - for the fuel supply line and lay the line to the side.





CAUTION!
The fuel system must have no pressure. Refer to --> [ High Side Fuel Pressure Releasing ] High Side Fuel Pressure Releasing.

- Loosen the high pressure fuel line union nut - lower arrow -.





- Disconnect the vacuum line - arrow - from the Intake Manifold Runner Control (IMRC) valve.





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





- Unlock the connector from the fuel pressure sensor - 1 - using the (T10118) and then disconnect the connector.





- Loosen the hose clamp - 2 -.





- Remove the bolt - 4 -.

- Disconnect the electrical connector - arrow -.

- Remove the noise insulation..

- Disconnect the charge air hose by lifting the clamp - 1 - and loosening the clamp - 2 -.





- Seal off the connections on the charge air cooler with a clean cloth.

- Remove the bolt - 1 - and remove the charge air pipe downward.





- Disconnect the electrical connectors - 1 though 3 - and remove the bracket from the intake manifold.





1. From the Camshaft Position (CMP) sensor

2. From the Knock Sensor (KS) 1

3. 8 pin harness connector for the fuel injectors

- Remove the intake manifold bracket by removing the nut - 1 - and bolt - 2 -.





- Remove the oil filter. Refer to --> [ Oil Filter, Cooler and Pressure Switch Assembly Overview ] Service and Repair.

- Loosen the line bracket - arrows -.





- Loosen the line - arrow - from the intake manifold.





- Remove the nuts - A - and loosen the bolts - arrows - from the intake manifold using the (T10347).





- Carefully pull the intake manifold and fuel rail away from the cylinder head just a little.

- Disconnect the electrical connector - arrow - from the intake manifold runner position sensor and remove the intake manifold.





- Cover the intake ports with clean cloths.

• The fuel injectors remain in the fuel rail.

Fuel Rail, Separating from the Intake Manifold

Conditions

• Intake manifold must be removed, removing, refer to --> [ Intake Manifold with Fuel Rail ] Intake Manifold With Fuel Rail.

Separating





- Remove the Evaporative Emission (EVAP) canister purge regulator valve - arrow - from the bracket.

- Loosen the double check valve - 1 - and the fuel line - 2 -.

- Open the hose clamp - 1 -.





- Remove both bolts - arrows - from the fuel rail.

- Disconnect the fuel rail from the intake manifold.

Installing

Install in reverse order of removal. When doing this note the following:

- Tighten the fuel line.

Tightening specification:

• Fuel rail assembly overview. Refer to --> [ Fuel Rail Assembly Overview ] Fuel Rail Assembly Overview.

Installing

Conditions

• The fuel injectors sit inside the cylinder head. Install the fuel injectors. Refer to --> [ Fuel Injectors ] Fuel Injectors.

Procedure

- Mount the intake manifold onto the cylinder head on the stud bolts (lower left and right).

• Make sure the fuel injectors are installed correctly and pay attention to the wiring bracket when mounting the intake manifold (located under the intake manifold).

• When installing the intake manifold, pull the manifold back out slightly and the fuel injectors will remain in the fuel rail, then remove the fuel injectors again from the fuel rail and insert the fuel injectors back into the cylinder head.

Install in reverse order of removal. When doing this note the following:

• When attaching the bracket onto the intake manifold, make sure it clips into both latches.





Tightening specifications:

• Intake manifold assembly overview. Refer to --> [ Intake Manifold Assembly Overview ] Intake Manifold Assembly Overview.

• Fuel rail assembly overview. Refer to --> [ Fuel Rail Assembly Overview ] Fuel Rail Assembly Overview.