Intake Manifold With Fuel Rail, Removing and Installing

Intake Manifold with Fuel Rail, Removing and Installing

If the intake manifold is replaced, the Intake Manifold Runner Position Sensor (G336) must be adapted to the Engine Control Module (ECM) (J623) with a.





Special tools, testers and auxiliary items required

• Multi-point socket (T10347)

• Oil filter wrench (3417)

• Torque Wrench (V.A.G 1331)

• Observe safety precautions => [ Safety Precautions ] Table of Contents.

• Observe the rules for cleanliness => [ Clean Working Conditions ] Fuel Supply System.

• To access the fuel injectors, the intake manifold and the fuel rail with intake manifold runner control valve must be removed.

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

• Intake manifold, assembly overview => [ Intake Manifold, Assembly Overview ] Intake Manifold, Assembly Overview

• Fuel Rail, Assembly Overview => [ Fuel Rail, Assembly Overview ] Fuel Rail, Assembly Overview

CAUTION!
Fuel system is under pressure! Fuel pressure must be reduced to a residual pressure before opening high pressure area of injection system, see procedure on page => [ Releasing Pressure in High Pressure Area ] Releasing Pressure In High Pressure Area.

Removing

Rabbit:

- Remove the charge air guide leading to the noise generator.

All:

- Remove the engine cover => [ Engine Cover, Removing and Installing ] Engine Cover, Removing and Installing.

- Clean the contact surface from the intake manifold to the cylinder head.

- Remove the air filter => [ Air Filter, Removing and Installing ] Air Filter, Removing and Installing.

- Separate the vacuum line - arrow - to the EVAP canister.





- Disconnect the following electrical connections:

• Intake Air Temperature (IAT) Sensor (G42) - 1 -

• Throttle Valve Control Module (J338) - 2 -

• Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 (N80)

• Camshaft Position (CMP) sensor (G40)

- Disconnect the vacuum line - 1 - at the separating point - 2 - and remove the crankcase ventilation hose - 3 -.





- Remove the bolts - arrows - for the fuel supply line and lay the line to the side.





• The fuel system must have no pressure.

- Open the fuel line union nut - lower arrow -.





- Disconnect the vacuum line - arrow - from the Intake Manifold Runner Control (IMRC) Valve (N316).





- Remove the bolts - arrows - for the coolant line from the intake manifold.





- Disconnect the electrical connector - 1 - from the Fuel Pressure Sensor (G247).





- Loosen the hose clamp - 2 -.





- Remove bolt - 4 -.

- Disconnect electrical connector - arrow -.

- Remove the noise insulation => Body Exterior 50 Noise Insulation.

- Remove the air guide pipe - items 1 and 2 -.





- Remove the bolt - 1 - and remove the air guide pipe downward.





- Disconnect the electrical connectors - 1 though 3 - and remove the bracket from the intake manifold.





- Remove the intake manifold bracket by removing the mounting nut - 1 - and bolt - 2 -.





- Remove the oil filter => [ Oil Filter, Oil Cooler and Oil Pressure Switch, Assembly Overview ] Oil Filter, Oil Cooler and Oil Pressure Switch, Assembly Overview.

- Loosen the wiring bracket - arrows -.





- Loosen the wire - arrow - from the intake manifold.





- Remove the nuts - A - and loosen the bolts - arrows - from the intake manifold using the Multi-point socket (T10347).





- Carefully pull the intake manifold and fuel rail away from the cylinder head just a little.

- Disconnect the electrical connector - arrow - from the Intake Manifold Runner Position Sensor (G336) and remove the intake manifold.





- Cover the intake channels with a clean rag.

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

- Disconnect the fuel rail from the intake manifold => [ Fuel Rail, Separating from the Intake Manifold ]

Installing

• The fuel injectors sit in the cylinder head. Fuel Injectors, Installing => [ Fuel Injectors, Removing and Installing ] Fuel Injectors, Removing and Installing

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

• Make sure the fuel injectors are installed correctly and pay attention to the wiring bracket when mounting the intake manifold (located under the intake manifold).

• When installing the intake manifold, the manifold must be pulled out slightly and the fuel injectors will stick in the fuel rail. Pull the fuel injectors out of the fuel rail and insert them in the cylinder head again.

The rest of the installation follows the reverse of the removal procedures. When doing this note the following:

- When attaching the wiring bracket onto the intake manifold, make sure it clips into both latches.





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

Fuel Rail Tightening Specifications, Assembly Overview => [ Fuel Rail, Assembly Overview ] Fuel Rail, Assembly Overview

Fuel Rail, Separating from the Intake Manifold

• Intake manifold must be removed, Intake manifold, removing => [ Intake Manifold with Fuel Rail, Removing and Installing ] Intake Manifold With Fuel Rail, Removing and Installing.

- Remove the Evaporative Emission (EVAP) Canister Purge Regulator Valve (N80) - arrow - from the bracket.





- Loosen the double check-valve - 1 - and the fuel line - 2 -.

- Open the hose clamp - 1 -.





- Loosen both bolts - arrows - from the fuel rail.

- Disconnect the fuel rail from the intake manifold.

Installing

- Tighten the fuel line.

- Further installation is performed in reverse order.

- Connect the electrical connector.

- Install intake manifold => [ Intake Manifold with Fuel Rail, Removing and Installing ] Intake Manifold With Fuel Rail, Removing and Installing.