Lower Intake Manifold, With Fuel Rail

Two Piece Intake Manifold

Lower Intake Manifold, with Fuel Rail

Special tools, testers and auxiliary items required

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

• Assembly Tool (T10118)

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 Injector Teflon Seal and Washer ].

• The seal - item 13 -=> [ Seal ] Two Piece Intake Manifold must also be replaced for the fuel injectors for cylinders 1, 3 and 5.

• If the fuel rail is removed, the fuel injector spring - arrow - must be replaced.





• Fuel rail, injectors and high pressure pump overview. Refer to => [ Fuel Rail, Injectors and High Pressure Pump Overview ] Two Piece Intake Manifold.

• Intake manifold overview. Refer to => [ Intake Manifold Overview ] Two 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 pressure. Refer to => [ High Side Pressure, Releasing ] High Side Pressure, Releasing.

- Disconnect the battery Ground (GND) cable with ignition turned off.

- Remove the noise insulation.

- Remove the upper intake manifold. Refer to => [ Upper Intake Manifold ]. Upper Intake Manifold

- Remove the high pressure pump. Refer to => [ High Pressure Pump ]. High Pressure Pump

- Remove the fuel rail connecting pipe - arrows -.





- Remove the lower intake manifold to cylinder head bolts - arrows -.





- Remove the oil dipstick guide tube to intake manifold bolt - 1 -.





- Remove the intake manifold support bolts - 2 - from the lower intake manifold.

- Remove the fuel rail bolts - arrows - for cylinders 2, 4 and 6.

- Carefully pull off the fuel rail from the fuel injectors.

- Remove the lower intake manifold.

• 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 ]. Fuel Injector Teflon Seal and Washer

• Seal the intake channels in cylinder head using a clean rag.

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 lower intake manifold with a new seal.

- Place the 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 the cylinder head with new bolts working from the inside to the outside.

• Tighten the lower intake manifold to cylinder head bolts.

- Install the fuel rail connecting pipe.





- Install the high pressure pump. Refer to => [ High Pressure Pump ]. High Pressure Pump

• Tighten the connecting line union nuts by hand and then tighten to specifications.

- Install the upper intake manifold. Refer to => [ Upper Intake Manifold ]. Upper Intake Manifold





• 1 Replace