Intake Manifold With Fuel Rail

Intake Manifold with Fuel Rail

The intake manifold runner position sensor (G336) must be adapted to the engine control module (J623) after removing or replacing the fuel rail vehicle diagnosis, testing and information system (VAS 5052) guided function.

• To access the fuel injectors, the intake manifold and the fuel rail with intake manifold runner control valve must be removed. (Depending on version, more or fewer work steps may be required).

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

• Intake Manifold Assembly Overview. Refer to => [ Intake Manifold Assembly Overview ] Intake Manifold Assembly Overview.

• Fuel Rail, Assembly Overview. Refer to => [ Fuel Rail Assembly Overview ] Fuel Rail Assembly Overview

Removing

- Remove engine cover. Refer to => [ Engine Cover with Air Filter Element ] Service and Repair.


Fuel system is under pressure! Fuel pressure must be reduced to a residual pressure before opening high pressure area of injection system. Refer to => [ Before Opening High Pressure Fuel Injection System ] Service and Repair.

- Disconnect all electrical harness connectors necessary.

- Disconnect vacuum hose between intake manifold and vacuum pump from intake manifold.

• This vacuum hose and the vacuum pump (attached to rear of cylinder head) are only installed on vehicles with automatic transmission.

• Disregard items 1 and 2 in the illustration.

- Disconnect hose connections - arrows - from valve cover.





• The fuel system must have no pressure.

- Pull the release button to disconnect the fuel supply line - 2 -.





- Pull the release button to disconnect the fuel return line - 3 -.

- Open both fuel lines at high-pressure pump.

- Disconnect electrical connector - 1 - from fuel pressure sensor (G247).





- Remove bolt - left arrow - for water line from intake manifold.





- Remove the oil dipstick and remove the bolt - arrow - on the oil dipstick guide tube.





- Open the clamp - 2 - and remove the air guide pipe from the throttle valve control module (J338).





• Ignore items - 1, 3 and 4 -.

- Separate the oil dipstick guide tube - 2 - at the separating point.





- Disconnect electrical connector - 1 - on throttle valve control module.





- Remove bolts - arrows - and remove throttle valve control module.

- Remove the nut - 2 - and bolt - 1 - and remove the intake manifold support.





- Remove all bolts from intake manifold.

- Carefully pull off intake manifold with fuel rail from cylinder head.

• The fuel injectors could remain stuck in the fuel rail.

- Fuel rail, removing and installing. Refer to => [ Fuel Rail ] Fuel Rail

Installing

- Installation is in reverse order.

• Tightening Specifications, Intake Manifold, Assembly Overview, refer to => [ Intake Manifold Assembly Overview ] Intake Manifold Assembly Overview.

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