Intake Manifold with Fuel Rail

Intake Manifold with Fuel Rail

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

• If the intake manifold is to be replaced, the intake manifold runner position sensor must be adapted to the Engine Control Module (ECM). Refer to "Guided Functions" in the vehicle diagnostic tester.

Special tools, testers and auxiliary items required

• Oil Filter Wrench (3417)

• Socket TORX(R) T30 (T10347)

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

• Assembly Tool (T10118)

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 seal) and the O-ring must always be replaced.

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

• Refer to => [ Fuel Rail and Injectors Overview ] Fuel Rail and Injectors Overview.

- Read the safety precautions before starting. Refer to => [ Safety Precautions ] Safety Precautions.

- Pay attention to the rules of cleanliness. Refer to => [ Clean Working Conditions ] Clean Working Conditions.

The fuel system is under pressure!

• Before opening the high pressure side components, the fuel pressure must be relieved to residual pressure. Refer to => [ High Side Fuel Pressure, Releasing ] Service and Repair.

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

- 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.

- Disconnect the vent line - arrow - from the Evaporative Emission (EVAP) canister and disconnect the EVAP canister purge regulator valve 1 connector.






- Disconnect the following electrical connectors as well:

1. Intake air temperature 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.






The fuel system must have no pressure. Refer to => [ High Side Fuel Pressure, Releasing ] Service and Repair.

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






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






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






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






- Loosen the hose clamp - 2 -.






- Remove the bolt - 4 -.

- Disconnect the electrical connector - arrow -.

- Remove the noise insulation..

- Remove the charge air hose by loosening the clamps - 1 and 2 -.






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

- 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.






1. Camshaft Position (CMP) sensor

2. Knock sensor 1

3. 8 pin connector for fuel injectors


- 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 Housing/Accessory Bracket Overview ] Service and Repair.

- Loosen the line bracket nuts - arrows -.






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






- Remove the nuts - A - and loosen the bolts - arrows - from the intake manifold using the Socket TORX(R) T30 (T10347).






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

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






- Cover the intake passages with clean cloths.

• The fuel injectors remain in the fuel rail.

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

Installing

Conditions

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

- Install 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 the reverse order of removal. Note the following:

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






Tightening specifications, refer to the following:

• => [ Intake Manifold Overview ] Intake Manifold Overview.

• => [ Fuel Rail and Injectors Overview ] Fuel Rail and Injectors Overview.

Fuel Rail, Separating from the Intake Manifold

Conditions

• The intake manifold must be removed. Remove the intake manifold. Refer to => [ Intake Manifold with Fuel Rail ] Intake Manifold with Fuel Rail.

Separating






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

- Loosen the double check valve - 1 - and the vent line - 2 -, if equipped.

- Open the hose clamp - 1 -.






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

- Remove the fuel rail from the intake manifold.

Installing

Install in reverse order of removal. Note the following:

- Tighten the fuel line.

Tightening specifications, refer to the following:

• => [ Fuel Rail and Injectors Overview ] Fuel Rail and Injectors Overview.

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