Lower Intake Manifold with Fuel Rail

Lower Intake Manifold with Fuel Rail

Special tools, testers and auxiliary items required

• Socket 14 mm (3150)

• Torque wrench (V.A.G 1331)

• Ratchet (V.A.G 1331/1)

• Open end wrench socket 17 mm (V.A.G 1331/2)

• SW 14 socket, open ring (V.A.G 1331/8)

• Socket (T40055)

• Hand vacuum pump (VAS 6213)

Removing

• The following removal and installation procedure is for the left intake manifold, lower. The procedure for the other side is identical.

CAUTION!
• Fuel system is under high pressure! Before opening high pressure components of the fuel injection system, pressure must be relieved to residual pressure => [ High-Pressure Fuel Injection System, Pressure Relief ] Service and Repair.

• Then wrap a clean rag around the connection and relieve residual pressure by carefully loosening the connection.

- Remove intake manifold upper => [ Upper Intake Manifold ] Upper Intake Manifold.

- Remove high-pressure line, thereby removing bolts and union nuts - 1 through 7 -.





- Disconnect electrical harness connectors:





1. Intake manifold runner position sensor 2 (G512)

2. Fuel pressure sensor (G247)

- Remove bolts and nuts - arrows - and remove intake manifold lower with fuel rail.

• Plug intake ports of the cylinder head with clean rags.

Installing

Installation is in reverse order of removal, note the following:

• Replace gaskets and O-rings.

• Lightly lubricate fuel injector O-rings with clean engine oil.

- Connect hand vacuum pump (VAS 6213) to intake manifold runner control vacuum actuator, as shown in illustration.





- Generate vacuum using hand vacuum pump.

• The intake flaps are opened.

• If the intake flaps are not opened, they could have seized when installing the intake manifold lower to the cylinder head.

- Install intake manifold lower and press fuel rail evenly onto fuel injectors.

- Fasten bolts - arrows - for intake manifold lower in a diagonal sequence and in stages.





- Remove hand vacuum pump from intake manifold runner control vacuum actuator.

- Connect electrical harness connectors - 1 - and - 2 -.

- Hand-tighten union nuts of high-pressure lines - 1 -, - 4 - and - 7 -.





- Make sure high-pressure lines are seated free of stress.

- To tighten SW 14 high pressure line at fuel rail, use torque wrench (V.A.G 1331) with socket insert AF 14, open ring (V.A.G 1331/8).





- To fasten high-pressure line (17 mm) to fuel rail, use torque wrench (V.A.G 1331) with Socket Insert AF 17 (V.A.G 1331/2).





- To fasten high-pressure line (14 mm) at high pressure pump use torque wrench (V.A.G 1331) with ratchet (V.A.G 1331/1) and socket 14 mm (3150).





- To fasten high-pressure line (17 mm) to high pressure pump, use torque wrench (V.A.G 1331) with reversible ratchet (V.A.G 1331/1) and socket (T40055).





Tightening Specifications