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)

Removing

• Read the safety precautions before starting. Refer to => [ Safety Precautions ] Safety Precautions.

• Follow the guidelines for clean working conditions. Refer to => [ Clean Working Conditions ] Clean Working Conditions.

• If a fuel injector is removed, then the combustion chamber Teflon(R) seal and the support washer must always be replaced => [ Combustion Chamber Teflon(R) Seal and Support Washer ] Combustion Chamber Teflon(R) Seal and Support Washer.

• The seal (- item 4 - in the => [ Fuel Injector Overview, Cylinders 1, 3 and 5 ] Fuel Injector Overview, Cylinders 1, 3 and 5) must also be replaced on fuel injectors for cylinders 1, 3 and 5.

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






• Fuel rail and injector overview. Refer to => [ Fuel Rail with Injector Overview ] Fuel Rail with Injector 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.

Always follow the safety precautions when reducing the high side fuel pressure.

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

- Remove the noise insulation.

- 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.

- Loosen the fuel rail connecting pipe union nuts - arrows - and remove the pipe.






- Remove the lower intake manifold to cylinder head bolts - arrows -.






- Remove oil dipstick guide tube bolt - 1 -.






- Remove the bracket - 2 - from the lower intake manifold.

- Remove the bolt - 3 -.

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

- Carefully remove the fuel rail from the fuel injectors.

- Remove the lower intake manifold.

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

• Plug the intake passages of the cylinder head with clean cloths.

Installing

Install in the reverse order of removal. Note the following:

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

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






- Install the lower intake manifold with a new gasket.

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

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

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

• Then, tighten the lower intake manifold to cylinder head bolts.

- Install the fuel rail connecting pipe.






• First, tighten the connecting pipe union nuts - arrows - hand tight and then tighten them to specifications.

• 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.

Tightening Specifications






• 1 Always replace