Generic Scan Tool

Intake Manifold Upper Section

Special tools, testers and auxiliary items required

• Assembly Tool (T10118)

• Hose Clip Pliers (V.A.G 1921)

• Socket Torx(R) T30 (T10347)

Removing

• It is necessary to remove the intake manifold and fuel rail in order to be able to get to the fuel injectors.

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

Fuel system is under pressure! Fuel pressure must be reduced to a residual pressure before opening high pressure area of injection system. Refer to => [ Releasing Pressure in High Pressure Area ] Description and Operation.

- Disconnect the battery Ground (GND) cable.

- Remove the engine cover.

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






- Disconnect the following electrical connectors.

1 EVAP canister purge regulator valve 1 (N80)
2 From the Knock Sensor (KS) 1 (G61)
3 From the Intake Manifold Runner Control (IMRC) valve (N316) , fuel pressure sensor (G247) and the Camshaft Position (CMP) sensor (G40)
4 From the fuel injectors
5 Throttle valve control module (J338)
6 Intake Air Temperature (IAT) sensor (G42)

• The fuel system must have no pressure.

• Use a clean cloth to absorb exiting fuel.

• Seal the open connections with clean caps and make sure no dirt has entered the fuel system.

- Remove the bolts - 1 and 2 - and the bracket for the connectors.






- Disconnect the connector - 2 - from the low fuel pressure sensor (G410).






- Disconnect the connector - 4 - from the CMP sensor.

- Open the hose clamps - 1 - and remove both fuel hoses.

- Open hose clamp - 3 -.

- Remove the EVAP line from the intake manifold upper section and from the separating point - arrows -.






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

- Guide the EVAP line under the fuel lines and move it to the side.

- Open the air guide hose clamp - arrow - and remove the hose from the throttle valve control module.






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






- Open the union nut and remove the fuel high pressure line from the intake manifold upper section.

- Open the union nut on the fuel rail for the fuel high pressure line.

- Remove the coolant line bolt - arrow - from the intake manifold upper section.






- Remove bolt - 2 -.






- Remove the intake manifold upper section bolts using (T10347).

- Remove the intake manifold upper section from the intake manifold lower section.

- Disconnect the connector from the cold start injector (N17).






• Seal the intake channels with a clean cloth.

- Remove the intake manifold lower section. Refer to => [ Intake Manifold Lower Section ] Intake Manifold Lower Section.

Installing

- Replace the connections for the fuel high pressure line on the high pressure pump and on the fuel rail.

- Mount the intake manifold onto the cylinder head on the stud bolts (lower left and right).

- Tighten the union nuts for the fuel high pressure line hand-tight.

- Tighten the intake manifold to the tightening specification (tighten the bolt starting from the inside toward the outside).

- Tighten the fuel high pressure line to the tightening specification.

- Install in reverse order of removal.

• Tightening specifications: Intake manifold assembly overview, refer to => [ Intake Manifold Overview ] Intake Manifold Overview

• Tightening specifications: Fuel rail assembly overview, refer to => [ Fuel Rail Overview ] Fuel Rail Overview