Lower Intake Manifold with Fuel Rail

Lower Intake Manifold with Fuel Rail

Special tools, testers and auxiliary items required

• Torque wrench (VAG 1331)

• Assembly tool (T10118)

• Multi point socket (T10347)

Removing

• Read safety precautions before beginning work. Refer to --> [ Safety Precautions ] Safety Precautions.

• Observe the rules for cleanliness. Refer to --> [ Clean Working Conditions ] Clean Working Conditions.

• If a fuel injector is removed, Teflon sealing ring of combustion chamber as well as O-ring must always be replaced. Refer to --> [ Fuel Injector Teflon Seal and Support Washer ] Fuel Injector Teflon Seal and Support Washer.

• Sealing ring --> [ (Item 5) Seal ] Fuel Rail with High Pressure Pump and Injectors Assembly Overview must also be replaced at fuel injectors for cylinders 1, 3 and 5.

• If fuel rail is removed, spring retainers for fuel injectors - arrow - must be replaced.





• Fuel rail with high pressure pump and fuel injectors assembly overview. Refer to --> [ Fuel Rail with High Pressure Pump and Injectors Assembly Overview ] Fuel Rail with High Pressure Pump and Injectors Assembly Overview.

• Intake manifold assembly overview. Refer to --> [ Intake Manifold Assembly Overview ] Intake Manifold Assembly Overview.

CAUTION!
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

• Route lines of all types (e.g. for fuel, hydraulic, Evaporative Emission (EVAP) system, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed.

• To prevent damages to the lines, make sure there is sufficient clearance to all moving or hot components.

CAUTION!
Follow safety measures for releasing fuel pressure on high pressure side. Refer to --> [ Releasing Pressure on High Pressure Side ] Service and Repair.

- Disconnect battery ground (GND) cable with ignition switched off.

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

- Remove the high pressure pump. Refer to --> [ High Pressure Pump ] High Pressure Pump.

- Remove fuel rail connecting pipe - arrows -.





- Remove - arrows - bolts of fuel rail for cylinders 2, 4 and 6.





- Carefully pull off fuel rail from fuel injectors.

- Remove the bolts - arrows - connecting the lower intake manifold tot the cylinder head with a socket (T10347).





- Remove lower intake manifold.

• If a fuel injector was removed from the cylinder head, the Teflon sealing ring must be replaced. Refer to --> [ Fuel Injector Teflon Seal and Support Washer ] Fuel Injector Teflon Seal and Support Washer.

• Seal the intake channels in the cylinder head using a clean cloth.

Installing

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

- Replace O-rings between fuel injectors and fuel rail and coat them lightly with clean motor oil.

- Replace spring retainers - arrow - at all fuel injectors.





- Position the lower intake manifold with a new gasket.

- Place fuel rail on and press evenly on to fuel injectors.

- Insert all bolts of intake manifold and of fuel rail by hand.

• First evenly tighten fuel rail to cylinder head with new bolts from inside to outside.

• Tighten the lower intake manifold/cylinder head bolts.

- Install fuel rail connecting pipe.





- Install high pressure pump. Refer to --> [ High Pressure Pump ] High Pressure Pump.

• First tighten the connecting line union nuts by hand and then tighten them to the specification --> [ (Item 21) Connecting pipe ] Fuel Rail with High Pressure Pump and Injectors Assembly Overview.

- Install the upper intake manifold. Refer to --> [ Upper Intake Manifold ] Upper Intake Manifold.





* Replace