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)

Removing

• Read the safety precautions before starting. Refer to => [ Safety Precautions ] Fuel Supply.

• Pay attention to the rules of cleanliness. Refer to => [ Clean Working Conditions ] Multiport Fuel Injection.

• If a fuel injector is removed, then the combustion chamber Teflon(R) seal and the washer must always be replaced. Refer to => [ Fuel Injector Teflon(R) Seal and Washer ] Fuel Injector Teflon(R) Seal and Washer.

• The seal (- item 13 - in the => [ Fuel Rail, Injectors and High Pressure Pump Overview ] Fuel Rail, Injectors and High Pressure Pump Overview) must also be replaced on the fuel injectors for cylinders 1, 3 and 5.

• If the fuel rail is removed, the fuel injector springs - 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.

Note the following whenever working inside the engine compartment due to limited space:

• Route all lines and cables in their original locations.

• Ensure sufficient clearance to all moving or hot components.

Follow the safety measures for releasing the high side fuel pressure. Refer to => [ High Side Fuel Pressure, Releasing ] Service and Repair.

- Disconnect the battery ground strap with the ignition turned off.

- Remove the noise insulation.

- 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 fuel rail connecting pipe - arrows -.

Engine Code BLV






Engine Code CNNA






- Remove the lower intake manifold to cylinder head bolts - arrows -.






- Remove the oil dipstick guide tube bolt - 1 -.






- Remove the bracket bolts - 2 - from the lower intake manifold.

- Remove the bolt - 3 -.

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

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

- Remove the lower intake manifold.

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

• Seal the intake passages in the cylinder head using clean cloths.

Installing

Installation is carried out in the reverse order while noting the following:

- Replace the O-rings between the fuel injectors and fuel rail and coat them lightly with clean engine oil.

- Replace the springs - arrow - on all the fuel injectors.






- Install the lower intake manifold with new seals.

- Place the fuel rail on and press it evenly onto the fuel injectors.

- Install all the bolts for the intake manifold and fuel rail by hand.

• First, evenly tighten the new fuel rail to cylinder head bolts working from the inside to the outside.

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

- Install the fuel rail connecting pipe - arrows -.

Engine code BLV






Engine code CNNA






• First, tighten the connecting pipe union nuts by hand and then tighten them to specification.

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

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






• 1 always replace