Intake Manifold and Injectors, with Plastic Manifold
Intake Manifold and Injectors, 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)
=> [ Upper Intake Manifold ]
=> [ Lower Intake Manifold, with Fuel Rail ]
=> [ Fuel Injectors ]
Upper Intake Manifold
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 (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.
- With the ignition switched off, disconnect the battery ground cable.
- Remove the engine cover.
- Pull the cover - 1 - forward and remove it upward.
- Disconnect the electrical connector - 1 - and disconnect the vacuum lines - arrows -.
- Remove the vacuum line - 4 - at the air guide hose.
• Ignore - item 1 -.
- Lay aside the air guide hose with connected crankcase ventilation hose - 3 - by loosening hose clamps - 2 and 5 -.
CAUTION!
Hose connector - 3 - must not be opened.
- Disconnect the electrical connector - 2 - for the Evaporative Emission (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.
- Disconnect the fuel lines - 1 and 4 - from the high pressure pumps.
- Remove the screws - 2 and 3 -.
- 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 a cloth and open carefully, as hot steam or hot coolant may escape when opening.
- Open the coolant expansion tank cap.
- Remove the crankcase ventilation hose 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 support.
- 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.
- Remove the coolant hose - arrow - and lay it aside.
- Remove the vacuum hose - arrow - to the intake manifold support.
- Remove the upper intake manifold bolts in sequence - 16 through 1 -.
- Remove the upper intake manifold from the engine compartment.
• Plug the intake ports of the cylinder head with clean cloths.
Installing
• Replace the 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.
- Check the gaskets in the intake manifold for damage and correct fit.
- Make sure the hoses or cables do not get caught.
- Tighten the upper intake manifold bolts in sequence - 1 through 16 -.
• Tightening specifications, refer to => [ Upper Intake Manifold ] Intake Manifold and Fuel Rail Assembly Overviews, with Plastic Manifold, and => [ Fuel Rail and Injectors ] Intake Manifold and Fuel Rail Assembly Overviews, with Plastic Manifold.
Further installation is performed in reverse order.
• 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.
Lower Intake Manifold, with Fuel Rail
Special tools, testers and auxiliary items required
• Torque wrench (5-50 Nm) (VAG 1331)
• Ring spanner insert (VAG 1331/2)
• Hand vacuum pump (VAS 6213)
Removing
• The following removal and installation procedure is for the left lower intake manifold. The procedure for the other side is identical.
CAUTION!
There is a risk of injury because the fuel is under very high pressure.
• The fuel pressure must be reduced to a residual pressure before opening the high pressure area of the fuel injection system. Refer to => [ High Side Fuel Pressure, Reducing ] Service Precautions.
- Reduce the fuel pressure in the high pressure side. Refer to => [ High Side Fuel Pressure, Reducing ] Service Precautions.
- Remove the vacuum hose from the intake flap vacuum diaphragm.
- Counter hold the threaded connection and remove the fuel high pressure line union nut from the high pressure pump.
- Disconnect the electrical connector - 1 - from the intake manifold runner position sensor and disconnect the vacuum hose - 2 -.
- Remove the union nut - 3 - while counter holding the threaded connection.
- Remove the bolts- arrows - and then remove the lower intake manifold and fuel rail.
CAUTION!
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 performed in reverse order of removal, noting the following:
• Replace the seals and O-rings.
• Lubricate the fuel injector O-rings lightly with clean engine oil.
The intake flaps must be moved in the - direction of the arrow - when installing the lower intake manifold.
- Connect the (VAS 6213) to the vacuum actuator connector as shown in the illustration.
- Generate vacuum using the (VAS 6213).
• The intake flaps are opened.
• If the intake flaps are not opened, they could have seized when installing the lower intake manifold in the cylinder head.
- Push the lower intake manifold evenly onto the injector valves.
- Tighten the bolts for the lower intake manifold diagonally and to the specifications.
• Tightening specifications, refer to => [ Upper Intake Manifold ] Intake Manifold and Fuel Rail Assembly Overviews, with Plastic Manifold.
- Remove the (VAS 6213) from the connection on the intake flap vacuum diaphragm.
- Counter hold the threaded connection and tighten the high pressure fuel line union nut to the high pressure pump.
- Tighten the union nut - 3 - while counter holding the threaded connection.
• Tightening specifications, refer to => [ High Pressure Pump Assembly Overview ] High Pressure Pump Assembly Overview.
- Make sure the high pressure line is free of tension.
Fuel Injectors
Special tools, testers and auxiliary items required
• Torque wrench (5-50 Nm) (VAG 1331)
• Tool insert, AF 14 (VAG 1331/6)
• Socket insert AF14 (VAG 1331/8)
• Tool set (T10133)
Removing
• The following describes removing and installing and the left injectors (cylinder bank 2).
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 upper intake manifold. Refer to => [ Upper Intake Manifold ].
- Remove the affected lower intake manifold. Refer to => [ Lower Intake Manifold, with Fuel Rail ].
- 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 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 injectors at same cylinder.
- Clean the cylinder head bore 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 the combustion chamber seal and the shaft of the fuel injector.
- Place the (T10133/5) with new combustion chamber seal - 1 - on 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 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.
• 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 injector must engage in the intended recess of the cylinder head.
• Coat the fuel injector O-rings with clean engine oil so they are easier to guide into the fuel rail.
• Replace all seals.
Further installation is performed in reverse order of removal, noting the following:
• Tightening specifications, refer to => [ Upper Intake Manifold ].
• High pressure line connections must not show any signs of damage.
• Do not change the angles of the high pressure lines.
- Only install the retaining tabs after high pressure lines have been tightened.
- Install the affected lower intake manifold. Refer to => [ Lower Intake Manifold, with Fuel Rail ].
- Install the upper intake manifold. Refer to => [ Upper Intake Manifold ].