Intake Manifold, Lower Section, With Fuel Rail

Intake Manifold, Lower Section, with Fuel Rail

Special tools, testers and auxiliary items required

• Torque Wrench (V.A.G 1331)

• Open End Wrench Socket 17 mm (V.A.G 1331/2)

• Hand Vacuum Pump (VAS 6213)

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.

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

- Reduce fuel pressure in high pressure area. Refer to => [ Before Opening High Pressure Fuel Injection System ] Service and Repair.

- Disconnect the vacuum hose on the vacuum diaphragm for the intake manifold flap.

- Counterhold the threaded connection and remove the fuel high pressure line union nut on the high pressure pump.

- Disconnect the connector - 1 - on the intake manifold runner position sensor and disconnect the vacuum hose - 2 -.

- Remove the union nut - 3 - while counterholding the threaded connection.





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

The engine could be destroyed.

• Cover the intake channels with a clean cloth to prevent small particles from getting into the engine through the intake channels in the cylinder heads.

Installing

Installation is in reverse order of removal, note the following:

• Replace seals and O-rings.

• Lubricate the fuel injector O-rings lightly with clean engine oil.

The intake manifold flaps must be moved in direction of - arrow - when installing the intake manifold lower section.





- Connect the (VAS 6213) to the vacuum diaphragm connection for the intake manifold flaps.





- 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 part of the intake manifold in the cylinder head.

- Push the intake manifold lower section evenly onto the injection valves.

- Tighten the bolts on the intake manifold lower section diagonally.

• Intake manifold lower section tightening specification - assembly overview

- Remove the hand vacuum pump from the connection on the vacuum diaphragm for the intake manifold flaps.

- Counterhold the threaded connection and tighten the fuel high pressure line union nut on the high pressure pump.

- Tighten the union nut - 3 - while counterholding the threaded connection.





• High pressure pump tightening specification. Refer to => [ High Pressure Pump Assembly Overview ] High Pressure Pump Assembly Overview

- Make sure the high pressure line is free of tension.