Intake Manifold with Fuel Rail, Removing and Installing

Intake Manifold with Fuel Rail, Removing and Installing

Special tools, testers and auxiliary items required

• Torque wrench (V.A.G 1331)






• Hose clamps up to 25 mm diameter (3094)






Perform the following:

Removing

• Follow all Safety Precautions. Refer to => [ Safety Precautions ] Safety Precautions.

• Follow the guidelines for cleanliness. Refer to => [ Clean Working Conditions ] Clean Working Conditions.

- First find out if a encoded radio is installed. If it is, get the anti-theft code.

- Disconnect battery => Electrical Equipment 27 Battery, disconnecting and connecting.


Fuel system is under pressure!

• Wear protective goggles and protective clothing in order to avoid injury and contact with the skin.

• Before loosening line connections, place cloths around the connection point. Then release pressure by carefully pulling off the line.

- Disconnect connectors - 7 - and - 8 -.






- Disconnect the hoses - 4 -, - 5 - and - 6 - from the intake manifold.

- Open clamps - 1 -, - 2 -, - 3 - and - 9 -, and remove intake hose - 10 -.

- Close off the coolant hoses leading to the throttle valve control module using hose clamps up to 25 mm diameter (3094) and remove them from the throttle valve control module.

- Remove the cable guide from the fuel rail.






- Disconnect the connector - 1 - from the fuel injectors and the connector - 4 - for the hall sensor (G40).

- Remove the oil dipstick tube - 1 - from the intake manifold - 2 -.






- Remove the bolts and nuts - arrows -.

- Pull the intake manifold - 2 - forward and out of the rear rubber bushings.

- Remove the intake manifold with the fuel rail and throttle valve control module.

- Plug the intake ports of the cylinder head with clean cloths.

If manifold must be replaced:

- Remove fuel rail with fuel injectors => [ Fuel Injectors, Removing and Installing ] Fuel Injectors, Removing and Installing.

- Remove the throttle valve control module and manifold absolute pressure sensor (G71) using the manifold absolute pressure sensor (G71). Refer to => [ Intake Manifold with Attachments, Assembly Overview ] Intake Manifold with Attachments, Assembly Overview.

Installing

Installation is performed in the reverse order of removal. When doing this note the following:

• Replace sealing rings between intake manifold and cylinder head.

• Tighten bolts for intake manifold starting inside working toward outside and in diagonal sequence.

• For the correct tightening specifications, refer to => [ Intake Manifold with Attachments, Assembly Overview ] Intake Manifold with Attachments, Assembly Overview.

- Connect the battery.

- Fuel System, Bleeding. Refer to => [ Fuel System, Bleeding ] Service and Repair.

- Erase the adaptation values and adapt the engine control module to the throttle valve control module. Refer to => Vehicle Diagnosis Tester "Guided Functions".