Intake Manifold
Intake Manifold
Special tools, testers and auxiliary items required
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Puller for Ignition Coil (T10095 A)
• Multi-Point Socket (T10347)
Removing
• Read the safety precautions before beginning work. Refer to => [ Safety Precautions ] Fuel Supply.
• Observe the rules for cleanliness. Refer to => [ Clean Working Conditions ] Multiport Fuel Injection.
• If a fuel injector is removed, the Teflon seal for the combustion chamber as well as the O-ring must always be replaced. Refer to => [ Fuel Injector Teflon Seal and Washer ] Fuel Injector Teflon Seal and Washer.
• The seal - item 1 -=> [ Seal ] Fuel Rail, Injectors and High Pressure Pump Overview must also be replaced on fuel injectors for cylinders 1, 3 and 5.
• If the fuel rail is removed, the fuel injector spring elements - arrow - must be replaced.
• Fuel rail, injectors and high pressure pump overview. Refer to => [ Fuel Rail, Injectors and High Pressure Pump Overview ] Fuel Rail, Injectors and High Pressure Pump Overview.
• Intake manifold overview. Refer to => [ Intake Manifold Overview ] Intake Manifold Overview.
CAUTION!
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
• Route lines of all types (for example, fuel, hydraulic, Evaporative Emission (EVAP), coolant, refrigerant, brake fluid and vacuum) and electrical wiring so that the original path is followed.
• To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot components.
CAUTION!
Follow the safety measures for releasing the high side fuel pressure. Refer to => [ High Side Pressure, Releasing ] High Side Pressure, Releasing.
Disconnect the battery Ground (GND) cable with the ignition turned off.
- Drain the coolant. Refer to => [ Draining and Filling ] Draining and Filling.
- Remove the coolant hoses - 1 and 2 -.
- Remove the oil dipstick guide tube bolt - 3 -.
- Remove the guide tube with the oil dipstick.
- Remove the ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.
- Remove the belt tensioner - item 25 -=> [ Belt Tensioner ] Cylinder Head Overview.
- Remove the generator.
- Remove the coolant hoses from the coolant pipe - 1 -.
- Disconnect the vacuum hoses from the Intake Manifold Runner Control (IMRC) valve (N316) - arrows -.
- Loosen the bolts - 2 - from the coolant pipe approximately 1 turn.
- Remove the - 3 - and remove the coolant pipe - 1 - from the intake manifold.
- Remove the connecting hose to the throttle valve control module (J338). Refer to => [ Air Filter Housing Overview ] Air Filter Housing Overview.
- Disconnect the connector from the throttle valve control module.
- Disconnect the connectors from the ignition coils with power output stages (N70, N127, N291, N292, N323, N324).
- Remove the ignition coils with power output stage. Refer to => [ Ignition Coils with Power Output Stages ] Service and Repair.
- Remove the wiring harness for the ignition coils with power output stages from the intake manifold.
CAUTION!
The fuel supply lines are under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before loosening the fuel lines, place a cloth around the connection point. Then release pressure by carefully loosening the union nuts.
- Lay a cloth around the threaded connection and loosen the union nut - arrow - from fuel supply hose. To do so, counter hold the fuel supply line using a wrench.
- Disconnect the high pressure line - 1 - as well as the low pressure line - 2 - from the high pressure pump. When doing this, counter hold the connection on the high pressure pump using a wrench.
- Disconnect the connectors - arrows -.
- Remove the high pressure pump bolts - item 15 -=> [ Bolt ] Fuel Rail, Injectors and High Pressure Pump Overview and remove the high pressure pump.
- Remove the fuel rail connecting line - arrows -.
- Disconnect the connecting hose - 1 - for crankcase ventilation from the cylinder head cover.
- Remove the rear intake manifold support bolt - arrow -.
- Remove the front intake manifold support bolt - arrow -.
- Disconnect the lines - arrows - from the intake manifold.
- Remove the right intake manifold support bolt - 1 -.
- Remove the intake manifold bolts - item 1 -=> [ Bolt ] Intake Manifold Overview.
- Remove the bolts - arrows - for the fuel rail for cylinders 2, 4 and 6.
- Carefully pull off the fuel rail from the fuel injectors.
- Remove the intake manifold downward and set it down on a suitable surface.
• Seal the intake passages in the intake manifold and in the cylinder head using clean cloths.
Installing
Installation is performed in the reverse order of removal, noting the following:
- Replace the O-rings between the fuel injectors and fuel rail and lubricate them lightly with clean motor oil.
- Replace the spring elements - arrow - on all fuel injectors.
- Install the intake manifold.
- Place the fuel rail on and press evenly onto the fuel injectors.
- Install all bolts for the intake manifold and fuel rail by hand.
• First evenly tighten the fuel rail to cylinder head with new bolts from the inside to the outside.
• Tighten the intake manifold to cylinder head bolts.
• Then tighten the intake manifold support bolts.
- Install the fuel rail connecting line - arrows -.
• Tighten the union nuts of the connecting line first by hand and then to specifications.
- Check the pump plunger - item 17 -=> [ Pump Plunger ] Fuel Rail, Injectors and High Pressure Pump Overview for damage, replace if necessary.
- Insert the lubricated pump plunger - 1 - with guide - 2 - perpendicularly into the cylinder head.
- Rotate the engine at the vibration damper slowly in engine rotation direction. When doing this, press the plunger in the - direction of the arrow - until it reaches the deepest point in the cylinder head.
- Install the high pressure pump.
• The O-rings for the high pressure pump must always be replaced.
• Before installing the fuel lines, first tighten the fuel line connection on the high pressure pump.
• High pressure line connection: 40 Nm.
• Low pressure line connection: 28 Nm.
• Tighten the union nuts of the fuel lines first by hand and then to specifications.
- Install the ribbed belt tensioner.
- Install the ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.
- Fill the cooling system. Refer to => [ Draining and Filling ] Draining and Filling.
Tightening Specifications
• 1 Replace