Intake Manifold and Fuel Rail Assembly Overviews, with Plastic Manifold
Intake Manifold and Fuel Rail Assembly Overviews, with Plastic Manifold
As a MY 2009 running change, a plastic intake manifold is being installed (it is possible to have mixed installation in MY 2009)
=> [ Vacuum Hoses Connection Diagram ]
=> [ Upper Intake Manifold ]
=> [ Lower Intake Manifold with Fuel Rail ]
=> [ Fuel Rail and Injectors ]
Vacuum Hoses Connection Diagram
1 Vacuum Hose with Check Valve
2 Intake Manifold Flap Vacuum Actuator
• For cylinder bank 1.
• Check using the hand vacuum pump (VAS 6213).
3 Intake Manifold Flap 2 Vacuum Actuator
• for cylinder bank 2.
• Check using the hand vacuum pump (VAS 6213).
4 Intake Manifold Tuning (IMT) Valve (N156)
5 Intake Manifold Change Over Valve Vacuum Actuator
• Check using the hand vacuum pump (VAS 6213).
6 Intake Manifold Runner Control (IMRC) Valve (N316)
• To remove and install, remove the intake manifold.
7 to Vacuum Reservoir
• Component location: Under the intake manifold.
• To remove and install, remove the intake manifold.
8 to Vacuum Reservoir
Upper Intake Manifold
1 Intake Manifold Change Over Valve Vacuum Diaphragm
2 Intake Manifold Tuning (IMT) Valve (N156)
3 Intake Flap Vacuum Diaphragm (Cylinder Bank 1)
• for cylinder bank 1 CVTS tumble flaps.
4 Bolt, 2.5 Nm
5 Intake Manifold Runner Position Sensor (G336)
• Cylinder bank 1.
• After replacing, perform "Adaptation" in "Guided Fault Finding" using the vehicle diagnostic, testing, and information system (VAS 5051B).
6 Gasket
• Replace if damaged.
• The open side faces the potentiometer.
7 Upper Intake Manifold
• Removing and installing, refer to => [ Upper Intake Manifold ] Intake Manifold and Injectors, with Plastic Manifold.
8 Bolt, 9 Nm
9 Throttle Valve Control Module (J338)
• After replacing, perform "Adaptation" in "Guided Fault Finding" using the vehicle diagnostic, testing, and information system (VAS 5051B).
10 O-ring
• Always replace.
11 O-ring
• Always replace.
12 Crankcase Housing Ventilation Adapter
• Tighten to 2.5 Nm.
13 O-ring
• Always replace.
14 Bolt, 9 Nm
15 Crankcase Housing Ventilation Pressure Regulator Valve
16 Upper Intake Manifold Bolts
• Tightening specification and sequence, refer to => [ Upper Intake Manifold, Tightening Specification and Sequence ].
17 Lower Intake Manifold Bolts
• Tightening specification and sequence, refer to => [ Lower Intake Manifold Bolt Tightening Specification ].
18 Lower Intake manifold
19 Gasket
• Always replace.
20 Intake Flap Vacuum Diaphragm (Cylinder Bank 2)
• For cylinder bank 2 CVTS tumble flaps.
21 Gasket
• Replace if damaged.
• The open side faces the potentiometer.
22 Intake Manifold Runner Position Sensor 2 (G512)
• Cylinder bank 2.
• After replacing, perform "Adaptation" in "Guided Fault Finding" using the vehicle diagnostic, testing, and information system (VAS 5051B).
23 Bolt, 2.5 Nm
24 Intake Manifold Runner Control (IMRC) Valve (N316)
Upper Intake Manifold, Tightening Specification and Sequence
- Tighten the upper intake manifold bolts - 1 through 16 - in sequence.
• First tighten to 8 Nm
• Second tighten to 11 Nm
Lower Intake Manifold Bolt Tightening Specification
- Tighten the bolts - arrows - for the lower intake manifold diagonally and in steps to 10 Nm.
Lower Intake Manifold with Fuel Rail
1 Bracket
• For the flange and fuel rail.
2 Gasket
• Always replace.
3 Sleeve
4 Lower Intake Manifold
• The intake manifold flaps must be in the working position (intake manifold channel opened all the way) when installing the lower intake manifold.
• Removing and installing, refer to => [ Lower Intake Manifold, with Fuel Rail ] Intake Manifold and Injectors, with Plastic Manifold.
5 Support Ring
• Replace if damaged.
• Make sure the support ring fits correctly when installing.
6 O-ring
• always replace.
• Lubricate with clean engine oil.
7 Spacer Ring
• Replace if damaged.
8 Fuel Injector
• Removing and installing, refer to => [ Fuel Injectors ] Intake Manifold and Injectors, with Plastic Manifold.
9 Combustion Chamber Seal
• Do not grease the ring or treat with any other lubricant.
• Always replace.
10 Actuator Lever
• For the vacuum actuator.
11 Seal
• Replace if damaged.
• Lift out with screwdriver to replace.
• Press in by hand.
12 Vacuum Hose
• From the intake manifold runner control valve.
13 Intake Manifold Runner Control Vacuum Actuator
14 Intake Manifold Runner Position Sensor 2 (G512)
15 Screws, 2.5 Nm
16 Threaded Support, 40 Nm
17 Cover
• for the spray nozzle valve and oil check valve.
18 to Vacuum Reservoir
19 High Pressure Fuel Line
20 Screws, 9 Nm
21 Fuel Rail
22 Bolt, 9 Nm
23 Bolt, 9 Nm
24 Screws, 0.3 Nm
Fuel Rail and Injectors
• The right fuel rail (cylinder bank 1) is shown in the illustration.
1 Screws, 0.3 Nm
2 Bracket
• For the flange and fuel rail.
3 Radial Adjustment
• Replace if damaged.
• Clip together with the support ring - item 8 -.
4 O-ring
• Always replace.
• Lubricate with clean engine oil.
5 Spacer Ring
• Replace if damaged.
6 Fuel Injector
• Removing and installing, refer to => [ Fuel Injectors ] Intake Manifold and Injectors, with Plastic Manifold.
7 Combustion Chamber Seal
• Do not grease the ring or treat with any other lubricant.
• Replacing, refer to => [ Fuel Injectors ] Intake Manifold and Injectors, with Plastic Manifold.
8 Support Ring
• Always replace.
• The fuel rail wields force via the support ring to hold the fuel injector tightly in the cylinder head.
9 Fuel Rail
• Removing and installing, refer to => [ Fuel Injectors ] Intake Manifold and Injectors, with Plastic Manifold.
10 Fuel Pressure Sensor (G247), 25 Nm
• Lubricate the threads with clean oil.
11 Lower Intake Manifold
• Removing and installing, refer to => [ Lower Intake Manifold, with Fuel Rail ] Intake Manifold and Injectors, with Plastic Manifold.