Fuel Injection System Components, Removing and Installing

Fuel Injection System Components, Removing And Installing

NOTE:
- Cylinder bank 1 is located on right side in direction of travel.
- Cylinder bank 2 is located on left side in direction of travel.

Intake manifold, removing and installing

NOTE: This procedure is described for vehicles with manual transmission. For vehicles with automatic transmission, Secondary Air Injection (AIR) pump must also be removed.

- Remove air distributor.







1 Unclip Wastegate Bypass Regulator Valve -N75- from fuel rail.
2 Disconnect connector at Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80-.
3 Loosen Sensor -1- for exhaust temperature -G235- and Bank 2 Exhaust Gas Temperature (EGT) Sensor 1 -G236- from intake manifold. The sensors remain connected. Make sure Ground (GND) cable is seated properly when reinstalling.
4 Remove hose to power brake booster at bulkhead.
5 Disconnect connector at Recirculating valve for turbocharger -N249-.
6 Remove the hose indicated. Hose leads to a vacuum reservoir (vacuum reserve).
7 Disconnect connectors at fuel injectors of cylinder bank 1 and cylinder bank 2.
8 Remove the hose indicated. This leads to the intake side of turbocharger bank 2.
9 Disconnect harness connector at Throttle Valve Control Module -J338-.
10 Disconnect harness connector at Charge Air Pressure Sensor -G31-.
11 Remove pressure line indicated
12 Remove the hose indicated; this leads to the recirculation valves.
13 Disconnect harness connector for Intake Air Temperature (IAT) Sensor -G42-.
14 Remove the hose indicated; this hose is used by crankshaft housing ventilation.
15 Remove the hose indicated. This leads to the intake side of turbocharger bank 1.
16 Disconnect fuel return line from fuel rail (use a clean rag to absorb escaping fuel).
17 Disconnect fuel supply line from fuel distributor.
18 Disconnect line indicated at EVAP valve.
- Unbolt intake manifold from cylinder heads.
- Carefully lift intake manifold off cylinder heads.

Installation of intake manifold is the same in reverse order. (Tightening torques for bolts: 10 Nm).







1 Fuel rail
2 to Intake manifold
3 Retaining clip
4 O-ring
- Always replace
5 Fuel pressure regulator
6 O-ring
- Always replace
7 Fuel injectors (Cylinder 1 Fuel Injector - N30- to Cylinder 3 Fuel Injector -N32-, Cylinder 4 Fuel Injector -N33- to Cylinder 6 Fuel Injector -N84- )
8 Retaining clip
- Make sure clip is correctly seated on fuel injector and fuel rail