Intake Manifold

Intake Manifold

Special tools, testers and auxiliary items required

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

• Socket XZN 8 (T40159)

• Pliers (3314)

Removing

• Follow the guidelines for a clean working environment when working on the fuel system. Refer to=> [ Clean Working Conditions ] Clean Working Conditions.

• Always follow these rules before and during work.

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

- Remove the noise insulation.

- Remove the charge air cooler. Refer to => [ Charge Air Cooler ] Charge Air Cooler.

- Disconnect the connectors for the glow plugs. Refer to => [ Glow Plugs ] Service and Repair.

- Remove the bolts - 2 - and set the coolant supply line aside.






- Remove the bolts - arrows - and set the fuel return line aside.






- Remove the bolt - 2 - and union nuts - 1 and 3 -, then remove the high pressure line.






- Remove the fuel rail. Refer to => [ Fuel Rail ] Fuel Rail.

- Remove the bolts - 2 - and remove the connecting tube - 1 -.






- Remove the upper bolts - arrows - for the support - 1 -.






- Release and disconnect the connector - 1 - from on the EGR vacuum regulator solenoid valve.






- Disconnect the connector - 2 -.






- Remove the bolt - 1 - for the oil dipstick guide tube.

- Remove the upper bolt - arrow -.

- Remove the bolts - arrows - for the intake manifold with the socket XZN 8 (T40159) diagonally from the outside towards the inside.






- Carefully remove the intake manifold.

Installing

Install in reverse order of removal. When doing this note the following:

• Replace seals.

- Tighten the bolts for the intake manifold starting on the inside and working toward the outside, in a diagonal sequence.

- Fill with coolant. Refer to => [ Draining and Filling ] Procedures.

Tightening Specifications