Removal and Installation
One Piece Intake Manifold
=> [ Intake Manifold ]
=> [ High Pressure Pump ]
=> [ Fuel Injectors ]
=> [ Fuel Injector Teflon Seal and Washer ]
Intake Manifold
Special tools, testers and auxiliary items required
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Ignition Coil Puller (T10095 A)
• Multi-Point Socket (T10347)
Removing
• Read the safety precautions before beginning work. Refer to => [ Safety Precautions ] Fuel Supply.
• Observe the rules for cleanliness. Refer to => [ Clean Working Conditions ] Multiport Fuel Injection.
• If a fuel injector is removed, the combustion chamber Teflon seal and O-ring must be replaced. Refer to => [ Fuel Injectors ].
• The Seal - item 1 -=> [ Seal ] One Piece Intake Manifold must also be replaced at fuel injectors for cylinders 1, 3 and 5.
• If fuel rail is removed, the fuel injector springs - arrow - must be replaced.
• Fuel rail, injectors and high pressure pump overview, through 07.07. Refer to => [ Fuel Rail, Injectors and High Pressure Pump Overview, through 07.07 ] One Piece Intake Manifold.
• Fuel rail, injectors and high pressure pump overview, from 08.07. Refer to => [ Fuel Rail, Injectors and High Pressure Pump Overview, from 08.07 ] One Piece Intake Manifold.
• Intake manifold overview. Refer to => [ Intake Manifold Overview ] One Piece Intake Manifold.
CAUTION!
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
• Route all lines and wires in their original locations.
• Make sure the wires have enough clearance to all moving or hot components.
CAUTION!
Follow the safety measures for releasing the high side fuel pressure. Refer to => [ High Side Pressure, Releasing ] High Side Pressure, Releasing.
- Disconnect the battery ground (GND) cable with the ignition turned off.
- Remove the connecting hose to the throttle valve control module (J338). Refer to=> [ Air Filter Housing Overview ] One Piece Intake Manifold.
- Disconnect the connector from the throttle valve control module.
- Disconnect the connector from the ignition coils with power output stages (N70, N127, N291, N292, N323, N324).
- Remove the ignition coils with power output stages. Refer to => [ Ignition Coils with Power Output Stages ] Service and Repair.
- Remove the wiring harness for the ignition coils with power output stages from the intake manifold.
- Remove the high pressure pump. Refer to => [ High Pressure Pump ].
- Remove fuel rail connecting pipe - arrows -.
- Remove the noise insulation.
- Remove the transmission fluid line bolt - arrow - from the transmission. Catch any leaking transmission fluid.
- Remove the front bumper.
- Bring the lock carrier into service position. Radiator Support
- Remove the bolt - 1 - for the oil dipstick guide tube.
- Remove the bracket - 2 - with the intake manifold runner control (IMRC) valve (N316) - 3 - from the intake manifold.
- Disconnect the vacuum hoses - arrows - from the IMRC valve - 3 -.
- Disconnect the connecting hose - 1 - for the crankcase ventilation from the cylinder head cover.
- Remove the bolt - arrow - for the intake manifold support on the left.
- Remove the bolt - arrow - for intake manifold support on the right.
- Disconnect the lines - arrows - from the intake manifold.
- Unclip the line - 2 - from retainer and move it clear.
- Remove the bolt - 1 - for the intake manifold support at the rear.
- Remove the intake manifold/cylinder head bolts - arrows - using (T10347).
- Remove the bolts - arrows - for the fuel rail for cylinders 2, 4 and 6.
- Carefully pull off the fuel rail from the fuel injectors.
- Remove the intake manifold downward and set it down on a suitable surface.
• If a fuel injector was removed form the cylinder head, then the Teflon seal must be replaced. Refer to => [ Fuel Injector Teflon Seal and Washer ].
• Seal the intake passages in the intake manifold and in the cylinder head using clean cloths.
Installing
Installation is performed in the reverse order of removal, noting the following:
- Replace the O-rings between the fuel injectors and fuel rail and lubricate them lightly with clean motor oil.
- Replace the spring - arrow - on all fuel injectors.
- Install the intake manifold.
- Place fuel rail on and press it evenly onto the fuel injectors.
- Install all the bolts for the intake manifold and fuel rail by hand.
• Evenly tighten the fuel rail to cylinder head with new bolts working from the inside to the outside.
• Tighten the intake manifold/cylinder head bolts.
• Tighten the bolts for the intake manifold support.
- Install fuel rail connecting pipe.
- Install the high pressure pump. Refer to => [ High Pressure Pump ].
• Tighten the connecting line union nuts by hand and then tighten them to specifications.
- If necessary, fill the transmission fluid.
• 1 Replace
High Pressure Pump
Removing
CAUTION!
• Follow the safety measures for releasing the high side fuel pressure. Refer to => [ High Side Pressure, Releasing ] High Side Pressure, Releasing.
• The fuel pipes are under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before disconnecting the fuel pipe, place a cloth around the connection point. Then release pressure by carefully loosening.
- Remove the lifting eye bolts - arrows - and lifting eye - A -.
Vehicles through 07.07
- Disconnect the connectors - arrows - and remove the low pressure hose - 1 - and high pressure line - 2 -. When doing this, counter hold the connection on the high pressure pump using a wrench.
- Disconnect the connector - A -, remove the bolts - arrows - and remove the high pressure pump - B - from the engine.
Vehicles from 08.07
- Disconnect the connector - arrow - and remove the low pressure hose - 1 - and high pressure line - 2 -. When doing this, counter hold the connection on the high pressure pump using a wrench.
- Disconnect the connector - A -, remove the bolts - arrows - and remove the high pressure pump - B - from the engine.
• Vehicles from 08.07 have a low pressure hose that is secured with hose clamps instead of union nuts. The low pressure hose secured with hose clamps must always be replaced because it is damaged when it is removed from the ridged connection.
Installing
- Check the high pressure pump plunger for damage; replace it if necessary.
- Insert the lubricated plunger - 1 - with guide - 2 - perpendicularly into the cylinder head.
- Rotate the engine at the vibration damper slowly in engine rotation direction. When doing this, press the plunger in the - direction of the arrow - until it reaches the deepest point in the cylinder head.
- Replace the high pressure pump O-ring.
- Install the high pressure pump and evenly tighten the bolts - arrows -.
Tightening specifications, refer to one of the following:
=> [ Fuel Rail, Injectors and High Pressure Pump Overview, through 07.07 ] One Piece Intake Manifold.
=> [ Fuel Rail, Injectors and High Pressure Pump Overview, from 08.07 ] One Piece Intake Manifold.
• The low pressure hose secured with hose clamps must always be replaced because it is damaged when it is removed from the ridged connection.
• Always replace the O-ring on the high pressure pump.
• Before installing the fuel lines, tighten the fuel line connection to the high pressure pump first.
• High pressure line connection: 40 Nm
• Low pressure line connection: 28 Nm
• Tighten the union nuts for the fuel lines first by hand and then to specifications.
Fuel Injectors
Read the safety precautions before beginning work. Refer to => [ Safety Precautions ] Fuel Supply.
• Each time a fuel injector is replaced, the Teflon seal must also be replaced. Refer to => [ Fuel Injector Teflon Seal and Washer ].
• The long fuel injectors for cylinders 1, 3 and 5 must not be separated.
Special tools, testers and auxiliary items required
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Tool Set (T10133)
Removing
- Remove the intake manifold. Refer to => [ Intake Manifold ].
- If the fuel injectors for cylinders 1, 3 and 5 will be removed, remove the corresponding fuel rail.
- Push the O-ring upward by hand as shown and remove it from the fuel injector.
- Install the (T10133/3) to (T10133/15).
- Install the (T10133/15) into the groove - arrow - on the fuel injector.
• The spring - arrow - must not be removed before removing the injector.
- Carefully remove the fuel injector.
Installing
- Thoroughly clean the injector bores in the cylinder head using (T10133/4).
- Check the plastic support washer - item 4 -=> [ Support Washer ] One Piece Intake Manifold for damage and replace it if necessary. Refer to => [ Fuel Injector Teflon Seal and Washer ].
- Replace the spring - arrow - and Teflon seal each time the fuel injector is removed. Refer to => [ Fuel Injector Teflon Seal and Washer ].
- Replace the O-rings between the fuel injectors and fuel rail and lubricate them lightly with clean motor oil.
• Seal - item 1 -=> [ Seal ] One Piece Intake Manifold must also be replaced at fuel injectors for cylinders 1, 3 and 5.
• The Teflon seal for the fuel injector may not be oiled or greased.
- Press the fuel injector by hand into the cylinder head bore until it stops.
- Check the fuel injectors for correct seating and installed position in the cylinder head.
If the fuel injectors for cylinders 1, 3 and 5 were removed:
- Place the fuel rail on and press evenly onto the fuel injectors.
- Tighten the fuel rail with new bolts uniformly.
Tightening specifications, refer to one of the following:
=> [ Fuel Rail, Injectors and High Pressure Pump Overview, through 07.07 ] One Piece Intake Manifold.
=> [ Fuel Rail, Injectors and High Pressure Pump Overview, from 08.07 ] One Piece Intake Manifold.
- Install the intake manifold. Refer to => [ Intake Manifold ].
Fuel Injector Teflon Seal and Washer
• The long fuel injectors for cylinders 1, 3 and 5 must not be separated.
Special tools, testers and auxiliary items required
• Tool Set (T10133)
Replacing the Teflon Seal
- Remove the intake manifold. Refer to => [ Intake Manifold ].
- Remove the fuel injectors. Refer to => [ Fuel Injectors ].
- Clean the fuel injector.
- Cut the seal - arrow - off with a knife. When doing so, do not let the knife blade come in contact with the injector.
- Remove the seal and clean the groove in the seal area - arrow -. Remove any deposits (coking) using a brass wire brush.
- Place the new seal - 1 - onto the (T10133/5). Slide the seal onto the (T10133/5) as far as it will go using (T10133/6) (the knurl faces toward the seal - 1 -).
- Turn the (T10133/6) around. The knurl no longer faces the seal. Slide the seal - 1 - near the end of the (T10133/5).
- Install the (T10133/5) and seal onto the fuel injector nozzle. Slide the seal onto the injector using (T10133/6).
The seal does not sit in the groove yet.
- Remove the (T10133/6) and the (T10133/5).
- Slide the seal by hand into the groove.
- Install the (T10133/11) onto the injector.
- Press the (T10133/7) over the seal to the stop on the (T10133/11).
- Remove the (T10133/7).
- Press the (T10133/8) over the seal to the stop on the (T10133/11).
- Remove the (T10133/8).
The Teflon seal now has the correct installed dimension.
Replacing the Support Washer
- Remove the O-ring - 3 -.
- Cut the support washer - 2 - with a small edge cutter and remove it.
- Remove the spring - 1 - from the fuel injector and slide off the (T10133/12).
- Install a new support washer - 1 - onto (T10133/13) and place this as shown on the fuel injector.
- Slide the support washer - 1 - using (T10133/14) (the knurled side faces toward the fuel injector) onto the fuel injector up to the first groove - arrow -.
- Turn the (T10133/14) around (knurled side no longer faces toward fuel injector). Slide the (T10133/14) over the support washer - 1 - in the - direction of the arrow - to the stop on the (T10133/12).
- Remove the (T10133/14).
Support washer is now the correct size.
- Install a new spring - 1 - for (T10133/12) and place a new O-ring - 3 - in front of the support washer - 2 -.
• The Teflon seal - arrow - must NOT be lubricated when installing the fuel injector.
- Install the fuel injectors. Refer to => [ Fuel Injectors ].
• The seal - item 1 -=> [ Seal ] One Piece Intake Manifold must also be replaced at fuel injectors for cylinders 1, 3 and 5.
• Install the intake manifold. Refer to => [ Intake Manifold ].