Intake Manifold and Injectors, with Magnesium Manifold
Intake Manifold and Injectors, with Magnesium Manifold
=> [ Intake Manifold ]
=> [ Fuel Injectors ]
Intake Manifold
Special tools, testers and auxiliary items required
• Torque wrench (5-50 Nm) (VAG 1331)
• Tool insert, AF 17 (V.A.G 1331/6)
• Socket insert AF 14 (V.A.G 1331/8)
• Assembly tool (T10118)
• Hose clamps up to 25 mm diameter (3094)
Removing
CAUTION!
• Fuel system is under high pressure! Before opening the high pressure components of the fuel injection system, the pressure must be relieved to a residual pressure. Refer to => [ High Side Fuel Pressure, Reducing ] Service Precautions.
• Then wrap a clean cloth around the connection and relieve the residual pressure by carefully loosening the connection.
• All cable ties opened or cut off during engine removal must be reinstalled at the same locations during installation.
- Pull the rear engine cover off - arrows -.
- Pull the front engine cover off - arrows -.
- Free up the fuel line and vacuum line to the Evaporative Emission (EVAP) canister on the air guide hose.
• Ignore - item 1 -.
- Remove the vacuum line - 4 - at the air guide hose.
- Lay aside the air guide hose with the connected crankcase ventilation hose - 3 - by loosening hose clamps - 2 and 5 -.
CAUTION!
Hose connectors - 3 - must not be opened.
- Disconnect the fuel lines - 1, 3, 4 and 6 -
- Remove bolts - 2 and 5 - and remove the fuel rail with high pressure lines.
- Remove bolt - 2 -, free up the wiring harness and press it to left.
- Remove bolt - 1 - and remove the left rear engine lifting eye.
- Remove bolt - 3 - and remove the left front engine lifting eye.
- Remove the bolt - 1 - and remove the right front engine lifting eye.
- Free up the wiring harness and press it to right.
- Disconnect the electrical connector - 1 - from the throttle valve control module.
- Remove the screws - arrows - and remove the throttle valve control module.
- Disconnect the vacuum lines - arrows - from the brake booster.
- Lay the vacuum lines aside.
• Ignore - item 1 -.
CAUTION!
Cover the coolant expansion tank cap with cloth and open carefully, as hot steam or hot coolant may escape when opening.
- Open the coolant expansion tank cap.
- Remove the crankcase ventilation house at - item 1 - and - item 2 - by pressing the release buttons.
- Clamp off the coolant hose - 4 - using the (3094) and remove the coolant hose from the intake manifold connection.
- Loosen the bolt - 5 - several turns.
- Remove the bolts - 3 - and press the crankcase ventilation pressure control valve carefully off the intake manifold support.
• Disregard - arrow -.
• To improve clarity, the removed engine is shown from the rear.
• Place a cloth under the intake manifold support to collect leaking coolant.
- Disconnect the electrical connector - 2 - for the EVAP canister purge regulator valve and remove the vacuum hose - 1 -.
- Remove the EVAP canister purge regulator valve from the bracket and lay aside with the hose connected.
- Remove the coolant hose - arrow - and lay it aside.
- Remove the vacuum hose - arrow - to the intake manifold support.
- Remove the vacuum hose - arrow -.
- Disconnect the electrical connectors for the:
1. Intake flap motor (brown connector)
2. Intake manifold runner position sensor
3. Variable intake manifold runner motor (black connector)
4. Intake manifold runner position sensor 2
- Remove the intake manifold bolts in sequence - 10 through 1 -.
- To avoid scratching the intake manifold, apply adhesive tape in the area of the high pressure lines.
- Next, raise the front of the intake manifold upward - arrow 1 -.
- Swing the intake manifold to the right side of the vehicle - arrow 2 -, under the high pressure fuel lines and out.
- Remove the intake manifold from the engine compartment.
• Plug the intake ports of the cylinder head with clean cloths.
Installing
• Replace gaskets and O-rings.
• Secure all hose connections using hose clamps appropriate for the model type.
• During installation, all cable ties must be reinstalled at the same location.
• Tightening specifications, refer to => [ Intake Manifold ] Intake Manifold and Fuel Rail Assembly Overviews, with Magnesium Manifold, and => [ Fuel Rail and Injectors ] Intake Manifold and Fuel Rail Assembly Overviews, with Magnesium Manifold.
Installation is performed in reverse order of removal, noting the following:
• High pressure line connections must not show any signs of damage.
• Do not change the angles of the high pressure lines.
- Hand tighten the union nuts for the high pressure lines.
- Make sure the high pressure lines are seated free of stress.
- To tighten the 14 mm diameter union nut on the high pressure lines, use the (VAG 1331) with the (VAG 1331/8).
- To tighten the 17 mm diameter union nut on the high pressure lines, use the (VAG 1331) with the (VAG 1331/6).
- Only install the retaining tabs after the high pressure lines have been tightened.
- Observe the safety precautions after connecting the battery.
- If necessary, fill the cooling system.
Fuel Injectors
Special tools, testers and auxiliary items required
• Torque wrench (5-50 Nm) (VAG 1331)
• Tool insert, AF 17 (VAG 1331/6)
• Socket insert AF 14 (VAG 1331/8)
• Tool set (T10133)
Removing
CAUTION!
• Fuel system is under high pressure! Before opening the high pressure components of the fuel injection system, the pressure must be relieved to a residual pressure. Refer to => [ High Side Fuel Pressure, Reducing ] Service Precautions.
• Then wrap a clean cloth around the connection and relieve the residual pressure by carefully loosening the connection.
- Remove the intake manifold. Refer to => [ Intake Manifold ].
• Seal the injector channels in the cylinder heads with clean cloths.
- Disconnect the electrical connectors from the fuel injectors.
- Remove the high pressure line - 5 - from the fuel rail.
- Remove the high pressure line - 7 - from the fuel rail. To do this, counter hold at the hex head with a open end wrench and loosen the union nut.
- Remove the screws - 1, 2, 3, 4, 6 and 8 -.
• Do not change the angles of the high pressure lines.
- Remove the fuel rail with the injectors.
If the fuel injectors cannot be pulled out of the cylinder head by hand, proceed as follows:
- Using a screwdriver, bend the retaining tabs - 1 - of the radial adjustment aside - arrow - and pull the support ring - 2 - off from the fuel injector.
- Remove the O-ring from the fuel injector.
- Install the (T10133/2A) in the groove on the fuel injector.
- Then position the (T10133/16) and remove the fuel injector by loosening the bolt - 1 -.
• When setting the (T10133/2A) in place, the radial adjustment can be destroyed, because the retaining tabs break.
- Carefully remove the old combustion chamber seal - arrow -, thereby cutting the seal open with a knife or spreading the seal open with a small screwdriver and pulling it forward and off.
- Make sure that the groove of the fuel injector does not become damaged. If the groove is damage, the fuel injector must be replaced.
Installing
• Replace the combustion chamber seal and O-ring.
• Replace the spacer ring if damaged.
• Lightly lubricate the fuel injector O-rings with clean engine oil.
• Reinstall the injector lines at the same cylinder.
- Clean the bore in the cylinder head with (T10133/4).
- Clip the radial adjustment - 1 - to the support ring - 2 -.
- When reinstalling a fuel injector, use a clean cloth to clean the combustion residue from the groove for combustion chamber seal and the shaft of the fuel injector.
- Place the (T10133/5) with new combustion chamber seal - 1 - on the fuel injector - 2 -.
- Slide the combustion chamber seal as far possible onto the (T10133/5) using the (T10133/6).
- Turn the (T10133/6) around and slide the combustion chamber seal into the groove.
• When pushing the combustion chamber seal onto the fuel injector, the seal spreads open. Therefore after pushing it on, it must be tightened again in 2 steps, as follows:
- Press the (T10133/7) with a slight turning motion (approximately 180 degrees) onto the fuel injector until it stops.
- Pull the (T10133/7) off again, turning it in the opposite direction.
- Press the (T10133/8) with a slight turning motion (approximately 180 degrees) onto the fuel injector until it stops.
- Pull the (T10133/8) off again, turning it in the opposite direction.
- Lubricate the new O-ring with clean engine oil before installing.
• The combustion chamber seal must not be oiled.
- Slide the fuel injector into the cylinder head bore until seated using the (T10133/9).
• The fuel injector must not be difficult to install. If necessary, wait as the combustion chamber seal continues to pull itself together.
- Make sure the fuel injectors are correctly positioned in the cylinder head.
• The electrical connectors for the fuel injectors must engage in the intended recess of the cylinder head.
- Press the fuel rail onto the fuel injectors with uniform pressure.
- Tighten screws - 1, 2, 3, 4, 6 and 8 - diagonally in stages.
• Tightening specifications, refer to => [ Fuel Rail and Injectors ] Intake Manifold and Fuel Rail Assembly Overviews, with Magnesium Manifold.
• High pressure line connections must not show any signs of damage.
• Do not change the angles of the high pressure lines.
- Hand tighten the union nuts for the high pressure lines.
- Make sure the high pressure lines are seated free of stress.
- To tighten the 14 mm diameter union nut on the high pressure line, use the (VAG 1331) with the (VAG 1331/8).
- To tighten the 17 mm diameter union nut on the high pressure line, use the (VAG 1331) with the (VAG 1331/6).
- Only install the retaining tabs after the high pressure lines have been tightened.
Further installation is performed in reverse order of removal, noting the following:
- Install the intake manifold. Refer to => [ Intake Manifold ].