Intake Manifold with Fuel Rail

Intake Manifold with Fuel Rail

=> [ Fuel Rail, Separating from the Intake Manifold ]

If the intake manifold is replaced, the intake manifold runner position sensor (G336) must be adapted to the engine control module (J623) using the vehicle diagnostic tester.

Special tools, testers and auxiliary items required

• Socket TORX T30 (T10347)

• Oil Filter Wrench (3417)

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

• Follow all safety precautions. Refer to => [ Safety Precautions ] Fuel Supply.

• Observe the rules for cleanliness. Refer to => [ Clean Working Conditions ] Fuel Supply.

• 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 overview. Refer to => [ Intake Manifold Overview ] Intake Manifold Overview.

• Fuel rail overview. Refer to => [ Fuel Rail Overview ] Fuel Rail Overview


Fuel system is under pressure! Before opening high pressure components of the fuel injection system, pressure must be reduced to residual pressure.

• Releasing pressure in the high pressure side. Refer to => [ High Side Fuel Pressure, Releasing ] Service and Repair.

Removing

- On vehicles with a noise generator: Remove the charge air pipe leading to the noise generator. Refer to => [ Charge Air Pipe to Noise Generator ] Charge Air Pipe to Noise Generator.






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

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

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

- Separate the vacuum line - arrow - from the Evaporative Emission (EVAP) canister.






- Disconnect the following electrical connections:

• Intake air temperature sensor (G42) - 1 -

• Throttle valve control module (J338) - 2 -

• EVAP canister purge regulator valve 1 (N80)

• Camshaft position sensor (G40)

- 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.






• The fuel system must have no pressure.

- Open the fuel line union nut - lower arrow -.






- Disconnect the vacuum line - arrow - from the intake manifold runner control valve (N316).






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






- Disconnect the electrical connector - 1 - from the fuel pressure sensor (G247).






- Loosen the hose clamp - 2 -.






- Remove the bolt - 4 -.

- Disconnect electrical connector - arrow -.

- Remove the noise insulation.

- Loosen the clamps - items 1 and 2 - and remove the charge air pipe.






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






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






- Remove the throttle valve control module bolts - arrows -.






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






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

- Loosen the wiring bracket - arrows -.






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






- Remove the nuts - A - and loosen the bolts - arrows - from the intake manifold using the socket TORX T30 (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 passages with a clean cloth.

• The fuel injectors could remain stuck in the fuel rail.

- Disconnect the fuel rail from the intake manifold. Refer to => [ Fuel Rail, Separating from the Intake Manifold ].

Installing

• The fuel injectors sit in the cylinder head. Fuel injectors, installing. Refer to => [ Fuel Injectors ] Fuel Injectors.

- 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 (under the intake manifold).

• When installing the intake manifold, the manifold must be pulled out slightly and the fuel injectors will stick in the fuel rail. Pull the fuel injectors out of the fuel rail and insert them in the cylinder head again.

The rest of the installation follows the reverse of the removal procedures. When doing this note the following:

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






Tightening specifications, intake manifold overview. Refer to => [ Intake Manifold Overview ] Intake Manifold Overview.

For tightening specifications, refer to fuel rail overview. Refer to => [ Fuel Rail Overview ] Fuel Rail Overview.

Fuel Rail, Separating from the Intake Manifold

• Intake manifold must be removed, intake manifold removing. Refer to => [ Intake Manifold with Fuel Rail ] Intake Manifold with Fuel Rail.

- Remove the EVAP canister purge regulator valve 1 (N80) - arrow - from the bracket.






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

- Open the hose clamp - 1 -.






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

- Remove the fuel rail from the intake manifold.

Installing

- Tighten the fuel line.

- Further installation is performed in reverse order.

- Connect the electrical connector.

- Install the intake manifold. Refer to => [ Intake Manifold with Fuel Rail ] Intake Manifold with Fuel Rail.