Lower Intake Manifold with Fuel Rail

Lower Intake Manifold with Fuel Rail

Special tools, testers and auxiliary items required

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Assembly Tool (T10118)

• 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 5 -=> [ Seal ] Fuel Rail, Injectors and High Pressure Pump Overview must also be replaced for 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.

- Remove the upper intake manifold. Refer to => [ Upper Intake Manifold ] Upper Intake Manifold.

- Remove the high pressure pump. Refer to => [ High Pressure Pump ] High Pressure Pump.

- Remove the fuel rail connecting pipe - arrows -.





- Remove the bolts for the fuel rail for cylinders 2, 4 and 6 - arrows -.





- Carefully pull off the fuel rail from the fuel injectors.

- Remove the lower intake manifold to cylinder heads bolts - arrows - using the (T10347).





- Remove the lower intake manifold.

• If a fuel injector was removed from the cylinder head, then the Teflon seal must be replaced. Refer to => [ Fuel Injector Teflon Seal and Washer ] Fuel Injector Teflon Seal and Washer.

• Seal the intake passages 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 lower intake manifold with a new seal.

- 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 new fuel rail to cylinder head bolts from the inside to the outside.

• Tighten the bolts lower intake manifold to cylinder head bolts.

- Install the fuel rail connecting pipe.





- Install the high pressure pump. Refer to => [ High Pressure Pump ] High Pressure Pump.

• First tighten the connecting line - item 21 -=> [ Connecting Pipe ] Fuel Rail, Injectors and High Pressure Pump Overview union nuts by hand and then to specification.

- Install the upper intake manifold. Refer to => [ Upper Intake Manifold ] Upper Intake Manifold.

Tightening Specifications





• 1 Replace