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)

• Assembly Tool (T10118)

• Socket TORX T30 (T10347)

Removing

• Read the safety precautions before beginning work. Refer to => [ Safety Precautions ] Fuel Supply.

• Observe the rules for cleanliness. Refer to => [ Clean Working Conditions ] Multiport Fuel Injection.

• If a fuel injector is removed, then the combustion chamber Teflon seal and the O-ring must always be replaced. Refer to => [ Fuel Injector Teflon(R) Seal and Washer ] Fuel Injector Teflon(R) Seal and Washer.

• The seal - item 22 - in the => [ Fuel Rail with High Pressure Pump and Injectors Overview ] Fuel Rail with High Pressure Pump and Injectors Overview, must also be replaced on the fuel injectors for cylinders 1, 3 and 5.

• If the fuel rail is removed, the fuel injector spring - arrow - must be replaced.






• Fuel rail with high pressure pump and injectors overview. Refer to => [ Fuel Rail with High Pressure Pump and Injectors Overview ] Fuel Rail with High Pressure Pump and Injectors Overview.

• Intake manifold overview. Refer to => [ Intake Manifold Overview ] Intake Manifold Overview.

Note the following whenever working inside the engine compartment due to limited space:

• Route all lines and wires in their original locations.

• Ensure sufficient clearance to all moving or hot components.

Follow the safety measures for releasing the high side fuel pressure. Refer to => [ High Side Fuel Pressure, Releasing ] Service and Repair.

- Turn off the ignition and disconnect the ground cable from the battery.

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

- Remove the high pressure pump. Refer to => [ High Pressure Pump ] High Pressure Pump.

- Remove the fuel rail connecting pipe - arrows -.






- Remove the fuel rail bolts - arrows - for cylinders 2, 4 and 6.






- Carefully remove the fuel rail from the fuel injectors.

- Remove the bolts - arrows - that connect the lower intake manifold to the cylinder using the socket TORX T30 (T10347).






- Remove the lower intake manifold.

• If a fuel injector was removed form the cylinder head, then the Teflon seal must be replaced. Refer to => [ Fuel Injector Teflon(R) Seal and Washer ] Fuel Injector Teflon(R) Seal and Washer.

• Seal the intake passages in cylinder head using a clean cloth.

Installing

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

- Replace the O-rings between the fuel injectors and fuel rail and coat them lightly with clean motor oil.

- Replace the springs - arrow - on all fuel injectors.






- Install the lower intake manifold with a new seal.

- Place the fuel rail on and press evenly onto the fuel injectors.

- Install all the bolts for the intake manifold and fuel rail by hand.

• First, evenly tighten the fuel rail to cylinder head with new bolts from the inside to the outside.

• Tighten the bolts that connect the lower intake manifold to the cylinder head.

- Install the fuel rail connecting pipe.






• First, tighten the connecting pipe union nuts by hand and then tighten them to specification.

• Ensure that the connecting pipe is not touching any other components.

- Install the high pressure pump. Refer to => [ High Pressure Pump ] High Pressure Pump.

- Install the upper intake manifold. Refer to => [ Upper Intake Manifold ] Upper Intake Manifold.






• 1 Replace