With Aluminum Intake Manifold
Intake Manifold
Special tools, testers and auxiliary items required
• Torque wrench (VAG 1331)
• SW 17 socket (VAG 1331/6)
• SW 14 socket, open ring (VAG 1331/8)
• Assembly tool (T10118)
Removing
CAUTION!
• Fuel system is under high pressure! Before opening high pressure components of the fuel injection system, pressure must be relieved to residual pressure. Refer to => [ Releasing Pressure on High Pressure Side ] Service and Repair.
• Then wrap a clean cloth around the connection and relieve residual pressure by carefully loosening the connection.
• All cable ties opened or removed during engine removal must be reinstalled at the same locations during installation.
CAUTION!
Observe safety precautions when disconnecting the battery.
- With ignition switched off, disconnect battery ground (GND) cable.
- Remove the front engine cover in - direction of arrows - if applicable.
- Remove the rear engine cover in - direction of arrows - if applicable.
- Disconnect breather line - arrow - to the Evaporative Emission (EVAP) canister purge regulator valve (N80) by pressing release button.
- Free up ventilation hose.
- Disconnect connector - 2 - from the EVAP canister purge regulator valve (N80).
- Remove ventilation hose - 3 - from intake manifold.
- Remove the EVAP canister purge regulator valve (N80) - item 1 - down from bracket.
CAUTION!
Fuel system is under pressure! Always follow safety measures before opening the system. Refer to => [ Safety Precautions ] Safety Precautions and => [ Releasing Pressure on High Pressure Side ] Service and Repair.
- Place a cloth around the threaded connection - arrow - and relieve the fuel pressure by briefly opening the line.
- Now remove fuel supply line - 3 - from the distribution piece.
Remove the air guide pipe => [ Air Guide Pipe ] Service and Repair.
- Remove bolts - 3, 4, 5 - and place crankcase ventilation pressure regulation valve slightly to side. Hose - 1 - can remain connected.
• To improve clarity, the engine is shown removed and from the rear.
- Now clamp coolant hose - arrow - with hose clamp (3094).
- Clamp coolant hose on crankcase housing ventilation valve - arrow - with a second hose clamp (3094).
- Now both coolant hoses can be removed from the throttle valve control module (J338).
- Remove crankcase ventilation hoses - 1 - and - 3 - together with coolant line - 2 -.
• To improve clarity, the engine is shown removed and from the rear.
CAUTION!
Fuel system is under pressure! Always follow safety measures before opening the system. Refer to => [ Safety Precautions ] Safety Precautions.
- Remove bolt - 1 - and union nut - 2 - and remove fuel supply line.
- Separate the electrical connector - 6 -.
- Remove bracket - 3 -.
- Open union nuts - 1, 2, 4, 5, 8, 9 - from the high pressure lines.
- Remove bolt - 7 -.
- Remove fuel rail with high pressure lines.
- Remove vacuum hose - arrow - from intake manifold.
- Disconnect connector - 1 - on throttle valve control module (J338) by removing the rubber cover over the release button.
- Remove the bolts - arrows -.
• To improve clarity, the engine is shown removed and from the rear.
- Remove the throttle valve control module (J338), ensure seal does not fall down.
- Remove cover - 1 - for oil filter housing - 3 -.
- Remove oil filter element - 2 -.
• Seal oil filter housing with a clean cloth.
- Disconnect the left and right electrical connectors - 1 - on the fuel metering valve (N290) and on the fuel metering valve 2 (N402) from the high pressure pump.
- Disconnect the left and right electrical connectors - 2 - on the Camshaft Position (CMP) sensor (G40) and on the Camshaft Position (CMP) sensor 2 (G163) on the cylinder head.
- Remove ground wire - 3 - from the right and left cylinder heads.
- Disconnect electrical connectors from the following:
1. Intake flap motor (V157) (brown connector)
2. Intake manifold runner position sensor (G336)
3. Variable intake manifold runner motor (V183) (black connector)
4. Intake manifold runner position sensor 2 (G512)
- Mark installation location of pipe clamps - arrow - for later assembly and remove them.
- Remove all four engine lifting eyes, left and right front and left and right rear - arrows -.
The engine lifting eye from cylinder head bank 2 is representative for all in the illustration.
- Remove intake manifold bolts - 10 to 1 - in the sequence.
• The intake manifold bolts - arrows - have a large bolt head.
- To avoid scratching intake manifold, apply adhesive tape in area of high pressure lines.
- Next, raise front of intake manifold upward - arrow 1 -.
- Swing intake manifold to right side of vehicle - arrow 2 -, under high pressure fuel lines and out.
- Remove intake manifold from engine compartment.
• Plug the intake ports of the cylinder head with clean cloths.
Installing
Installation is performed in reverse order of removal, noting the following:
• Replace gaskets and O-rings.
• Secure all hose connections with hose clamps appropriate for the model.
• During installation, all cable ties must be reinstalled at the same location.
- Replace intake manifold gaskets while watching locating point - 1 -. It must be inserted in the hole - arrow -.
- Be aware of the alignment pins - 2 - when setting the intake manifold in place.
- Tighten intake manifold bolts - 1 to 10 - in sequence.
• High pressure line connections must not show any signs of damage.
• Do not change the angles of the high pressure lines.
- Hand tighten the union nuts for the high pressure lines.
- Make sure the high pressure lines are seated free of stress.
- To tighten SW 14 union nut on high pressure lines, use torque wrench (VAG 1331) with socket insert AF 14, open ring (VAG 1331/8).
- To tighten SW 17 union nut for high pressure lines, use the torque wrench (VAG 1331) with SW 17 socket (VAG 1331/6).
- Only install retaining tabs after high pressure lines have been tightened.
- Observe safety precautions after connecting battery.
- Fill cooling system, as necessary. Refer to => [ Cooling System, Draining and Filling ] Cooling System, Draining and Filling.
Tightening Specifications
