Intake Manifold, Lower Section, with Fuel Rail

Intake Manifold, Lower Section, with Fuel Rail

Special tools, testers and auxiliary items required

• Torque Wrench 5-50 Nm (V.A.G 1331)

• Ring Spanner Insert (V.A.G 1331/2)

• Hand Vacuum Pump (VAS 6213)

Removing

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


There is a risk of injury because the fuel is under very high pressure.

• The fuel pressure must be reduced to residual pressure before opening the high pressure area of the fuel injection system. Refer to => [ Before Opening High Pressure Fuel Injection System ] Service and Repair.

- Reduce fuel pressure in high pressure area. Refer to => [ Before Opening High Pressure Fuel Injection System ] Service and Repair.

- Remove the supercharger.

- Push the vacuum hoses to the side.

- Disconnect the fuel pressure sensor (G247) connector - 4 -.






- Remove the union nut - 1 - while counterholding the threaded connection.

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

- Disconnect the connector - 2 - on the intake manifold runner position sensor and remove the vacuum hose - 3 -.


The engine could be destroyed.

• Cover the intake channels with a clean cloth to prevent small particles from getting into the engine through the intake channels in the cylinder heads.

Installing

Installation is performed in reverse order of removal, noting the following:

• If a fuel injector was removed from the cylinder head, then the Teflon seal must be replaced.

• Replace seals and O-rings.

• Lubricate the fuel injector O-rings lightly with clean engine oil.

Move the intake manifold flaps in direction of - arrow - when installing the intake manifold lower section.






- Connect (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 lower section of the intake manifold in the cylinder head.

- Press the intake manifold lower section evenly on the fuel injectors.

- Tighten the bolts and nuts diagonally on the intake manifold lower section according to the tightening specification.

• Tightening specification for the intake manifold lower section => [ Lower Intake Manifold Section - Tightening
Specification and Sequence ] Lower Intake Manifold Section Overview

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

- Connect the fuel pressure sensor (G247) connector - 4 -.






- Counterhold the threaded connection and tighten the union nut - 1 -.

- Make sure the high pressure line is free of tension.

- Install the supercharger.