Intake manifold lower-part with fuel rail, removing and installing

WARNING: This page is about a different car, the 2009 Audi A4, 2008 Audi A4, 2007 Audi A4, 2006 Audi A4, and 2005 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Special Tools - Intake Manifold Lower-Part With Fuel Rail, Removing And Installing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools, testers and auxiliary items required

Socket 14 mm 3150
Torque wrench V.A.G 1331
Ratchet V.A.G 1331/1
Open end wrench socket 17 mm V.A.G 1331/2

SW 14 socket, open ring V.A.G 1331/8
Socket T40055

Special tools, testers and auxiliary items required

Fig 2: Identifying Hand Vacuum Pump VAS 6213

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Hand vacuum pump VAS 6213

Removing

NOTE:

The following removal and installation procedure is for the left intake manifold lower-part. The procedure for the other side is identical.

CAUTION:

Fuel system is under high pressure! Before opening high pressure components of the fuel injection system, pressure must be relieved to residual pressure → Procedure that must be performed before opening the high-pressure fuel injection system. Pay close attention! .
Then wrap a clean rag around the connection and relieve residual pressure by carefully loosening the connection.

Remove upper part of intake manifold → Intake manifold upper-part, removing and installing .

Fig 3: Removing High-Pressure Line, Thereby Removing Bolts And Union Nuts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove high-pressure line, thereby removing bolts and union nuts - 1 through 7 -.

Fig 4: Removing/Installing Intake Manifold Bolts And Nuts

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Disconnect electrical harness connectors:

Intake Manifold Runner Position Sensor 2 G512
Fuel Pressure Sensor G247

Remove bolts and nuts - arrows - and remove intake manifold lower-part with fuel rail.

NOTE:

Plug intake ports of the cylinder head with clean rags.

Installing

Installation is in reverse order of removal, note the following:

NOTE:

Replace gaskets and O-rings.
Lightly moisten fuel injector O-rings with clean engine oil.

Fig 5: Connecting Hand Vacuum Pump VAS 6213 To Intake Manifold Runner Control Vacuum Actuator

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Connect Hand Vacuum Pump VAS 6213 to intake manifold runner control vacuum actuator, as shown in illustration.
Generate vacuum using hand vacuum pump.

The intake flaps are opened.

NOTE:

If the intake flaps are not opened, they could have seized when installing the lower part of the intake manifold in the cylinder head.

Install lower part of intake manifold and press fuel rail evenly onto fuel injectors.

Fig 6: Removing/Installing Intake Manifold Bolts And Nuts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fasten bolts - arrows - for intake manifold lower-part in a diagonal sequence and in stages.
Remove hand vacuum pump from intake manifold runner control vacuum actuator.
Connect electrical harness connectors - 1 - and - 2 -.

Fig 7: Removing High-Pressure Line, Thereby Removing Bolts And Union Nuts

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Hand-tighten union nuts - 1 - , - 4 - and - 7 - of high-pressure lines, and then for lines - 2 - , - 3 - , - 5 - and - 6 -.
Make sure high-pressure lines are seated free of stress.

Fig 8: Fastening High-Pressure Line At Fuel Rail Using Torque Wrench V.A.G 1331 With Open End Wrench Socket V.A.G 1331/8

Courtesy of VOLKSWAGEN UNITED STATES, INC.

To fasten high-pressure line (14 mm) on fuel rail, use Torque Wrench V.A.G 1331 with Socket Insert AF 14 V.A.G 1331/8.

Fig 9: Fastening High-Pressure Line At Fuel Rail Using Torque Wrench V.A.G 1331 With Open End Wrench Socket V.A.G 1331/2

Courtesy of VOLKSWAGEN UNITED STATES, INC.

To fasten high-pressure line (17 mm) to fuel rail, use Torque Wrench V.A.G 1331 with Socket Insert AF 17 V.A.G 1331/2.

Fig 10: Fastening High-Pressure Line (14 mm) At High Pressure Pump Use Torque Wrench V.A.G 1331 With Ratchet V.A.G 1331/1 And Socket 14 mm 3150

Courtesy of VOLKSWAGEN UNITED STATES, INC.

To fasten high-pressure line (14 mm) at high pressure pump use torque wrench V.A.G 1331 with ratchet V.A.G 1331/1 and socket 14 mm 3150.

Fig 11: Fastening High-Pressure Line At High Pressure Pump Using Torque Wrench V.A.G 1331 With Ratchet V.A.G 1331/1 And Socket 17 mm T40055

Courtesy of VOLKSWAGEN UNITED STATES, INC.

To fasten high-pressure line (17 mm) to high pressure pump, use Torque Wrench V.A.G 1331 with Reversible Ratchet V.A.G 1331/1 and Socket T40055.

Torque specifications

Component		Nm
Intake manifold lower-part to cylinder head		9
High pressure lines to	High pressure pump	25
	Fuel rail	25