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Removing and installing fuel rail > < Intake manifold - exploded view
Removing and installing intake manifold
Removing and installing intake manifold
Special tools and workshop equipment required
   
t  Torque wrench -V.A.G 1331-
  W00-0427
t  Ratchet -V.A.G 1331/1-
  W00-10045
t  Open end spanner insert, AF 17 -V.A.G 1331/6-
  W00-1126
t  Socket -T40055-
  W00-10099
t  Pliers -3314-
  W00-0019
t  Bit XZN 8 -T40159- for vehicles with aluminium intake manifold
  W00-10572
t  Socket T30 -T10405- for vehicles with plastic intake manifold
Removing
  WARNING
t  Always read rules for cleanliness and instructions for working on fuel system → Chapter.
t  Follow these instructions and rules for cleanliness before starting work and while working on the fuel system.
–  Remove engine cover panel → Chapter.
–  Take noise insulation off cylinder head cover.
  W00-10757
–  Unplug electrical connectors -5, 6, 7 and 8- at glow plugs.
  Caution
Make sure that no wire connection is damaged when unplugging the connectors; otherwise the entire wiring harness must be renewed. When unplugging the connectors, do not compress the pliers -3314- with too much force so that the support sleeve is not damaged.
  A23-10265
–  Apply groove -arrow A- of pliers -3314- to collar of support sleeve -arrow B- and pull connectors off glow plugs.
  M97-0523
–  Unscrew union nuts at high-pressure pump -1- and fuel rail -5- and remove high-pressure fuel pipe -4-.
–  Remove bolts -arrows- for high-pressure fuel pipe.
–  Move wiring harness -6- clear.
  A23-10273
–  Pull fuel pipe connections -2 and 3- off high-pressure pump.
  A23-10273
–  Remove bolts -arrows- securing the two fuel pipes.
  Note
Do not bend fuel lines.
  Caution
t  Observe rules for cleanliness when working on the injection system.
t  Plug open connections with suitable sealing caps immediately.
  A23-10272
–  Unplug following electrical connectors:
1 - Fuel pressure sender -G247-
2 - Fuel pressure regulating valve -N276-
3 - Variable intake manifold motor -V183-
4 - Intake manifold flap motor -V157-
5 - Exhaust gas recirculation valve -N18-
  A23-10264
–  Open hose clip -arrow- securing air hose and disconnect hose downwards from intake manifold flap motor -V157-.
–  Remove bolt on bracket for oil dipstick.
–  Detach connecting pipe for exhaust gas recirculation from exhaust gas recirculation valve -N18-.
–  Remove bolts securing intake manifold in diagonal sequence starting from outside and working inwards.
–  Remove intake manifold.
Installing
Installation is carried out in the reverse order; note the following:
–  Renew seals and/or gaskets.
–  Tighten bolts securing intake manifold in diagonal sequence starting from outside and working inwards.
l  Tightening torque: intake manifold - exploded view → Item
l  Tightening torque for connecting pipe for exhaust gas recirculation: refer to exploded view of intake manifold → Chapter „Intake manifold - exploded view“
l  Tightening torque for high-pressure pipes: refer to exploded view of fuel system → Chapter
  A24-10598

Removing and installing fuel rail > < Intake manifold - exploded view