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 must be adapted to the Engine Control Module (ECM) using a vehicle diagnostic tester.

Special tools, testers and auxiliary items required

• Oil Filter Wrench (3417)

• Socket TORX T30 (T10347)

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

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

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

• To access the fuel injectors, the intake manifold and the fuel rail with the intake manifold runner control valve must be removed.

• The combustion chamber seal (Teflon(R) seal) and the O-ring must always be replaced.

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

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

The fuel system is under pressure! Before opening the high pressure components of the fuel injection system, pressure must be reduced to a residual pressure. Refer to => [ High Side Fuel Pressure, Releasing ] Service and Repair.

Removing

- On vehicles with a noise generator: Remove the charge air hose from the noise generator. Refer to => [ Charge Air Hose to Noise Generator ] Charge Air Hose 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.

GTI and Eos

- Remove the fan shroud. Refer to => [ Fan Shroud ] Fan Shroud.

Continuation for All

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






- Disconnect the following electrical connectors:

• Intake air temperature sensor - 1 -

• Throttle valve control module - 2 -

• EVAP canister purge regulator valve 1

• Camshaft position sensor

- 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.






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






- Disconnect the connector - 1 - from the fuel pressure sensor.






- Loosen the hose clamp - 2 -.






- Remove the bolt - 4 -.

- Disconnect the connector - arrow -.

- Remove the noise insulation. Refer to one of the following:

GTI and Tiguan

Eos and Passat

CC

- Remove the charge air hose - A - and then cover the charge air cooler with a clean cloth.






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






- Remove the bracket bolts - arrows - and 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 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.

Installing

• The fuel injectors must be installed in the cylinder head. Install the fuel injectors. Refer to => [ Fuel Injectors ] Fuel Injectors.

- Mount the intake manifold onto the cylinder head 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 procedure. Note the following:

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






Tightening specifications, refer to the following:

=> [ Intake Manifold Overview ] Intake Manifold Overview.

=> [ Fuel Rail and Injector Overview ] Fuel Rail and Injector Overview.

Fuel Rail, Separating from the Intake Manifold

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

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






- Loosen the 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.

- Install in the reverse order of removal.

- Connect the electrical connector.

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

Tightening Specifications