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)

• Ring Spanner Insert (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.

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

• Then wrap a clean rag around the connection and relieve residual pressure by carefully loosening the connection.

- Remove the intake manifold. Refer to => [ Intake Manifold ] Intake Manifold.

- Remove the vacuum hose from the intake manifold flap vacuum diaphragm.

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

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

- Counterhold the threaded connection and remove the union nut - 3 -.





• It is necessary to disconnect the connector from the fuel pressure sensor (G247) in order to be able to remove the right intake manifold lower section.

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

Move the intake manifold flaps in direction of - arrow - when installing the intake manifold lower section.





- Connect the (VAS 6213) to the connection on the intake manifold flap vacuum diaphragm, as illustrated.





- Generate vacuum using hand vacuum pump.

• The intake flaps are opened.

• If the intake manifold flaps are not opened, they may get jammed when installing the intake manifold lower section on the cylinder head.

- Press the intake manifold lower section evenly on the fuel injectors.

- Tighten the bolts on the intake manifold lower section diagonally according to the tightening specification.

• Tightening specification, refer to => [ Intake Manifold Assembly Overview ] Intake Manifold Assembly Overview

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

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

- Counterhold the threaded connection and tighten the union nut - 3 -.





• Tightening specification, refer to => [ High Pressure Pump Assembly Overview ] High Pressure Pump Assembly Overview

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