Lower Intake Manifold With Fuel Rail

Lower Intake Manifold 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)

Removing

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

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

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

• To reduce remaining residual pressure, lay a clean cloth around the connector and carefully loosen connector.

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

- Disconnect the electrical connector on the fuel pressure sensor (G247) - 2 -.






- Remove the union nut - 1 -.

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

• Plug the intake ports of the cylinder head with clean rags.

Installing

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

• If a fuel injector was removed form 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.

- Press the lower section of the intake manifold with the fuel rail evenly onto the fuel injectors.

- Tighten the bolts and nut - arrows - on the lower section of the intake manifold diagonally in stages.






• Tightening specifications, refer to => [ Intake Manifold, Lower Section, with Fuel Rail Overview ] Intake Manifold, Lower Section, With Fuel Rail Overview, => [ High Pressure Line, Installing ] Intake Manifold, Lower Section, With Fuel Rail Overview.

- Disconnect the electrical connector - 2 - on the fuel pressure sensor.

- Install the high pressure line - 1 - on the fuel rail. Refer to => [ High Pressure Lines ] Service and Repair.






• Check fuel system for leaks.