Intake Manifold With Fuel Rail, Removing and Installing

Intake Manifold With Fuel Rail, Removing And Installing

CAUTION: Before opening a component of the high-pressure section, the fuel pressure must be released. Pay absolute attention to the procedure.

NOTE:
- To access the fuel injectors, the intake manifold and the fuel rail with intake manifold runner control valve must be removed. (Depending on version, more or fewer work steps may be required).
- The combustion chamber seal (Teflon) and the O-ring must always be replaced.

Removing
- Remove engine cover.
- Disconnect all electrical harness connectors from the intake manifold and fuel rail.
- Disconnect vacuum hose between intake manifold and vacuum pump from intake manifold.

NOTE: This vacuum hose and the vacuum pump (attached to rear of cylinder head) are only installed on vehicles with automatic transmission.







- Disconnect fuel line - arrow - (catch escaping fuel and plug the open connections immediately).







- Disconnect hose connections - arrows - from valve cover.







- Remove both bolts - 1 and 2 - from coolant pipe.







- Remove bolt from oil line - 1 - and from coolant pipe - 2 - .







- Remove both fuel lines at high-pressure pump.
- Open hose clamps and pull intake hose off from Throttle Valve Control Module J338 and intake manifold.







- Disconnect electrical connector - 1 - from Fuel Pressure Sensor G247.







- Pull oil dipstick out and remove bolt - 2 - for oil dipstick guide tube.







- Remove bolt - 1 - for oil line.







- Remove nut - arrow - from intake manifold support (if necessary, remove Throttle Valve Control Module J338 to access the support nut).







- Separate oil dipstick guide tube - 2 - at separation point and remove bolt - 1 - for intake manifold bracket.
- Remove all bolts from intake manifold.
- Carefully remove intake manifold with fuel rail from cylinder head.

NOTE: The fuel injectors could remain stuck in the fuel rail.

- Fuel rail, removing and installing

Installing
- Installation is in reverse order of removal.

Mounting bolts for intake manifold 9 Nm
Bolt for intake manifold support 23 Nm
Nut for intake manifold support 10 Nm
Fuel supply line to high pressure pump 30 Nm
Fuel return line to high pressure pump
(replace) 25 Nm
Bolts for Intake Flap Motor V157 7 Nm