Intake Manifold

Intake Manifold

If the fuel rail is removed or replaced, the intake manifold runner position sensor (G336) must be adapted to the Engine Control Module (ECM) (J623). Use the vehicle diagnostic tester in "Guided Functions".

Special tools, testers and auxiliary items required

• Assembly Tool (T10118)

• Hose Clip Pliers (V.A.G 1921)

• Socket Torx(R) T30 (T10347)

• Hazet Oil Filter Wrench (2171-1) or an Oil Filter Wrench (3417)

• 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.

• Intake manifold overview, refer to => [ Intake Manifold Overview ] Intake Manifold Overview.

• Fuel rail overview, refer to => [ Fuel Rail Overview ] Fuel Rail Overview


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

- Disconnect the battery Ground (GND) cable.

- Remove the engine cover. Refer to => [ Engine Cover ] Service and Repair.

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






- Disconnect the following electrical connectors.

1 Evaporative Emission (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)

Disconnect the connector - 1 - from the CMP sensor.






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






- Disconnect the vacuum line - 1 - at the separating point - 2 -.






- Remove the crankcase ventilation hose - 3 -.

- Open the spring clamp - upper arrow - and remove the fuel supply line from the high pressure pump.






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

• 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 vacuum line - arrow - from the IMRC valve.






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






- Disconnect the connector from the fuel pressure sensor - 1 -.






- Loosen the mounting nut - 1 - slightly and remove the bolt - 2 - completely.






- Remove the oil filter with a (2171-1) or a (3417).






- Remove the intake manifold bolts using (T10347).

• The throttle valve control module must be removed in order to remove any bolts that are not accessible and not using the (T10347)

- Carefully pull the intake manifold with the fuel rail away from the cylinder head slightly.

- Disconnect the connector - 1 - from the intake manifold runner position sensor and remove the intake manifold.






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

• Seal the intake channels with a clean cloth.

- Separate the intake manifold from the fuel rail. Refer to => [ Fuel Rail ] Fuel Rail.

Installing

• Make sure the fuel injectors are installed correctly.

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

- Install in reverse order of removal.

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

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