Intake Manifold

Intake Manifold

Special tools, testers and auxiliary items required

• Socket Insert XZN 10 (T10385)

• Socket XZN 8 (T40159)

• Torque Wrench (5-5) Nm (V.A.G 1331)

• Hose Clip Pliers (VAS 6362)

• Ratchet, Reversible (V.A.G 1331/1)

• Engine Bung Set (VAS 6122)


• Follow the safety precautions when working on the diesel direct injection system. Refer to => [ Safety Precautions ] Diesel Fuel Injection.

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

Always follow these instructions before and during work.

Removing

• Make sure no contaminants enter the fuel system when removing the intake manifold.

• Seal off the connections in the fuel system using plugs from the engine bung set (VAS 6122).

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

- Remove the protective strip, if equipped.

- Remove the high pressure line and fuel line bolts - arrows - on the intake manifold.






- Disconnect the fuel injector - A - connectors, the exhaust pressure sensor 1 connector - B - and the fuel pressure sensor connector - C -.






- Remove the coolant line bolts - arrows - from the intake manifold and lay the line in front of the intake manifold.

- Unclip the wiring harness from the wiring guide for the glow plugs.


Always follow the procedure "Glow Plug Connector, Disconnecting and Connecting".

- Disconnect the glow plug connectors. Refer to => [ Glow Plug Connector, Disconnecting and Connecting ] Glow Plug Connector, Disconnecting and Connecting.

- Remove the high pressure line between the high pressure fuel pump and fuel rail.

- Reposition the hose clamp - arrow - using hose clip pliers (VAS 6362) and remove the line from the fuel rail.






- Before removing, clean the return line connection on the fuel injectors (for example using a commercially available detergent).

- Dry the return line connections.

- Cover the return line connections with a cloth.

- Remove the fuel return line connections from the fuel injectors. Pull them upward to release them - arrow -.






• Maintain clean working conditions. Dirt and contaminants must not enter the return lines and the connections on the fuel injectors.

- Reposition the hose clamps using hose clip pliers (VAS 6362) and remove the fuel return line.

- Reposition the hose clamp - 4 - using the hose clip pliers (VAS 6362) and remove the fuel return line from the high pressure fuel pump.






- Seal the lines so that the fuel system is not contaminated by dirt, etc.

- Remove the fuel return lines.

- Disconnect the EGR vacuum regulator solenoid valve connector - 1 - and the throttle valve control module connector - 3 -.






- Loosen the clamp - 4 - and remove the charge air hose.

- Remove the oil dipstick bracket - arrow -.


Make sure the connecting pipe coupling element does not bend or stretch. Cracks could develop.

- Disconnect the connecting pipe - 2 -.

- Remove the intake manifold bolts using socket XZN 8 (T40159) in a diagonal sequence working from the outside to the inside.

- Remove the intake manifold.

Installing

Install in the reverse order of removal. When doing this note the following:

• Always replace seals.

• When installing the high pressure line or fuel lines, make sure no dirt or contaminants enter the fuel system.

• Only remove the sealing plugs right before installing the fuel lines.

• Do not change the angles of the high pressure lines

• Make sure lines connections are securely fastened.

• Do not swap supply and return lines.

- Tighten the intake manifold bolts in a diagonal sequence working from the inside to the outside:

• Tightening specifications, see - item 2 - in the => [ Intake Manifold and Attachments Overview ] Intake Manifold and Attachments Overview.

- Tighten the high pressure line union nuts by hand.

- Make sure the high pressure line is free of tension.

- Use torque wrench (5-50 Nm) (V.A.G 1331) with ratchet, reversible (V.A.G 1331/1) and the socket (T40055) to tighten the high pressure line.






Tightening Specifications

• => [ Fuel Rail and Injectors Overview ] Service and Repair

• => [ Intake Manifold and Attachments Overview ] Intake Manifold and Attachments Overview

- Fill the fuel system. Refer to => [ Fuel System, Filling and Bleeding ] Fuel System, Filling and Bleeding.