Intake Manifold

Intake Manifold

Special tools, testers and auxiliary items required

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Pliers (3314)

• Socket XZN 8 (T40159) (Vehicles with a Aluminum Intake Manifold)

• T30 TORX Socket (T10405) Vehicles with a Plastic Intake Manifold)

Removing

- Remove the engine cover. Refer to => [ Engine Cover ] Engine Cover.


Be careful not to damage the wire connections when removing the connectors. Otherwise the entire wiring harness has to be replaced. Do not squeeze the pliers (3314) too hard when removing the connectors otherwise the protective sleeve will get damaged.

- Disconnect the connectors on the fuel injectors - A -, the exhaust pressure sensor 1 - B - and the fuel pressure sensor - C -.






- Remove the coolant line bolts - arrows - from the intake manifold and lay the line in front of the intake manifold.

- Install the pliers (3314) with the groove - arrow A - on the collar of the support sleeve - arrow B -.






- Carefully disconnect the connector from the glow plugs in the - direction of the arrow -.






- Remove the fuel return lines from the rail, the injectors as well as from the high pressure pump.

- Remove the bolt - arrow - and remove the return line.






- Remove the high pressure line between the high pressure pump and the rail.

with a Plastic Intake Manifold

- Remove the fuel injector lines to the injectors. Refer to => [ Fuel System Component Overview ] Fuel System Component Overview.

- Remove the fuel rail. Refer to => [ Fuel System Component Overview ] Fuel System Component Overview.

Continuation for All

- Disconnect the connectors from the EGR vacuum regulator solenoid valve - 1 - and the throttle valve control module - 3 -.






- Open the clamp - 4 - and remove the charge air hose.

- Remove the bolts from the oil dipstick connection - arrow - and from the Exhaust Gas Recirculation (EGR) connecting pipe - 2 -.






- Remove the bolts for the intake manifold in a diagonal sequence starting at the outside and working toward the inside using the socket XZN 8 (T40159) or the T30 TORX socket (T10405).

- Remove the intake manifold.

Installing

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

- Replace the gaskets

- Tighten the intake manifold bolts in a diagonal sequence starting from the inside and working toward the outside. Tightening specification, see - item 2 - in the => [ Intake Manifold and Attachments Overview ] Intake Manifold and Attachments Overview.

with a Plastic Intake Manifold

- Install the fuel rail. Refer to => [ Fuel System Component Overview ] Fuel System Component Overview.

- Install the fuel injector lines to the injectors. Refer to => [ Fuel System Component Overview ] Fuel System Component Overview.