Intake Manifold Lower Section With Fuel Rail

Intake Manifold Lower Section 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 section. 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. Refer to => [ Before Opening High Pressure Fuel Injection System ] Service and Repair.

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

- Remove upper section of intake manifold. Refer to => [ Intake Manifold Upper Section ] Intake Manifold Upper Section.

- Remove the 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-section with fuel rail.





• Plug the 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 coat fuel injector O-rings with clean engine oil.

- 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.

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





- Fasten the bolts - arrows - for intake manifold lower-section 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 -.

- Tighten the union nuts - 1 -, - 4 - and - 7 - on the high pressure lines hand tight. Then tighten the lines - 2 -, - 3 -, - 5 - and - 6 -.





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

- To fasten high-pressure line (14 mm) on fuel rail, use (V.A.G 1331) with (V.A.G 1331/8).





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





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





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





Tightening Specifications