Intake Manifold With Fuel Rail

WARNING: This page is about a different variant/trim than selected.

The intake manifold runner position sensor -G336- must be adapted to the engine control module -J623- after removing or replacing the fuel rail vehicle diagnosis, testing and information systemVAS 5052 "Guided Function".

NOTE:

To access the fuel injectors, the intake manifold and the fuel rail with intake manifold runner control valve must be removed. (Depending on version, more or fewer work steps may be required).

The combustion chamber seal (Teflon) and the O-ring must always be replaced.

Intake manifold. Refer to INTAKE MANIFOLD ASSEMBLY OVERVIEW .

Fuel Rail. Refer to FUEL RAIL ASSEMBLY OVERVIEW .

Removing

-- Remove engine cover.

WARNING:

Fuel system is under pressure! Fuel pressure must be reduced to a residual pressure before opening high pressure area of injection system. Refer to BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM .

-- Disconnect all electrical harness connectors necessary.

-- Disconnect vacuum hose between intake manifold and vacuum pump from intake manifold.

NOTE:

This vacuum hose and the vacuum pump (attached to rear of cylinder head) are only installed on vehicles with automatic transmission.

Disregard items 1 and 2 in the illustration.

-- Disconnect hose connections -arrows- from valve cover.

-- Disconnect vacuum line -2- to EVAP canister.

Fig 1: Disconnecting Hose Connections From Cylinder Head Cover And Disengage Fuel Supply Line (Absorb Fuel Outflow) And Hose Connection From EVAP Canister

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-- Disconnect fuel supply line -arrow-.

Fig 2: Fuel System Must Have No Pressure

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NOTE:

The fuel system must have no pressure.

-- Open both fuel lines -2 and 3- to high pressure pump.

Fig 3: New High Pressure Pumps Connections

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-- Remove bolt and nut -arrows-, then push the right front coolant pipe to the side with the coolant hoses still connected.

Fig 4: Locating Coolant Pipes

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-- Remove nit -arrow- for the oil dipstick guide tube.

Fig 5: Oil Dipstick Guide Tube - Tightening Specifications

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This step only for engine code CDMA

-- Disconnect electrical connector -3-.

Fig 6: Identifying Bolt And Hose, Removal

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-- Remove bolt -arrow-.

-- Remove hose -2-.

-- Loosen hose clamp -1- and lay the air guide pipe Turbocharger Recirculating Valve -N249- to the side with the hose -4- still connected.

All engine codes

-- Loosen hose clamp -2- and remove the air guide pipe from the throttle valve control module -J338-.

Fig 7: Air Guide Hose Bolts, Air Guide Pipe Hose Clamps & Electrical Harness Connector

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NOTE:

Ignore items -1, 3 and 4-.

-- Disconnect connector -1- on the intake air temperature sensor -G42-.

Fig 8: Disconnect Connector Intake Air Temperature (IAT) Sensor

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NOTE:

Disregard -arrow-.

-- Disconnect electrical connectors:

Fig 9: Identifying Crankcase Ventilation Hose, Removal

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2 - For injector valves, remove the connectors from the bracket

3 - For evaporative emission (EVAP) canister purge regulator valve -N80-

4 - Intake Flap Motor -V157-

5 - Fuel pressure sensor -G247- and Camshaft Position (CMP) Sensor -G40-, remove the connectors from the bracket

-- Disconnect electrical connector -1-.

Fig 10: Identifying Throttle Valve Control Module Electrical Connector And Bolts

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-- Remove bolts -arrows- and remove Throttle Valve Control Module -J338-.

-- Remove nut -2- and bolt -1- and remove intake manifold support.

Fig 11: Identifying Intake Manifold Support, Removal

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-- Disconnect electrical connector -1- from Fuel Pressure Sensor -G247-.

Fig 12: Fuel Pressure Sensor G247 Electrical Connector & Oil Dipstick Guide Tube Bolt

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-- Remove all bolts from intake manifold.

-- Carefully pull off intake manifold with fuel rail from cylinder head.

NOTE:

The fuel injectors could remain stuck in the fuel rail.

-- Fuel rail, removing and installing. Refer to FUEL RAIL .

Installing

-- Installation is in reverse order of removal.

Tightening Specifications, Intake Manifold. Refer to INTAKE MANIFOLD ASSEMBLY OVERVIEW .
Tightening specifications, Fuel rail. Refer to FUEL RAIL ASSEMBLY OVERVIEW .