Intake Manifold

Special tools and workshop equipment required 

• Socket insert XZN 10T10385
• Socket XZN 8 T40159
• Torque Wrench (5-5) Nm V.A.G 1331
• Hose Clip Pliers VAS 6362
• Ratchet, Reversible V.A.G 1331/1
• Engine Bung Set VAS 6122

Removing 

-- Remove the engine cover. Refer to ENGINE COVER .

-- Remove the protective strip, if equipped.

-- Remove the high pressure line and fuel line bolts -arrows- on the intake manifold.

Fig 1: Identifying Fuel Line Bolts On Intake Manifold

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-- Disconnect the fuel injector -A- connectors, the exhaust pressure sensor 1 -G450- connector -B- and the fuel pressure sensor -G247- connector -C-.

Fig 2: Identifying Connector -C- From Fuel Pressure Sensor

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

-- Unclip the wiring harness from the wiring guide for the glow plugs.

-- Disconnect the glow plug connectors. Refer to GLOW PLUG CONNECTOR, DISCONNECTING AND CONNECTING .

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

-- Reposition the hose clamp -arrow- using hose clip pliers VAS 6362 and remove the line from the fuel rail.

Fig 3: Identifying Hose Clip Pliers VAS 6362 To Reposition Hose Clamp -Arrow- And Remove Line From Fuel Rail

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Before removing, clean the return line connection on the fuel injectors (for example using a commercially available detergent).

-- Dry the return line connections.

-- Cover the return line connections with a cloth.

-- Remove the fuel return line connections from the fuel injectors. Pull them upward to release them -arrow-.

Fig 4: Identifying Direction To Remove Fuel Return Line Connections From Fuel Injectors

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-- Reposition the hose clamps using hose clip pliers VAS 6362 and remove the fuel return line.

-- Reposition the hose clamp -4- using the hose clip pliers VAS 6362 and remove the fuel return line from the high pressure fuel pump.

Fig 5: Identifying Hose Clip Pliers VAS 6362 To Reposition Hose Clamp -4- And Remove Fuel Return Line From High Pressure Fuel Pump

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-- Seal the lines so that the fuel system is not contaminated by Dirt, etc.

-- Remove the fuel return lines.

-- Disconnect the EGR vacuum regulator solenoid valve -N18- connector -1- and the throttle valve control module -J338- connector -3-.

Fig 6: Identifying EGR Vacuum Regulator Solenoid Valve -N18- Connector -1-, Throttle Valve Control Module -J338- Connector -3- And Clamp -4-

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

-- Remove the oil dipstick bracket -arrow-.

-- Disconnect the connecting pipe -2-.

-- Remove the intake manifold bolts using socket XZN 8 T40159 in a diagonal sequence working from the outside to the inside.

-- Remove the intake manifold.

Installing 

Install in reverse order of removal. When doing this note the following:

• Always replace seals.
• When installing the high pressure line or fuel lines, make sure no Dirt or contaminants enter the fuel system.
• Only remove the sealing plugs right before installing the fuel lines.
• Do not change the angles of the high pressure lines
• Make sure lines connections are securely fastened.
• Do not swap supply and return lines.

-- Tighten the intake manifold bolts in a diagonal sequence working from the inside to the outside:

• Tightening specifications, see -item 2- in the INTAKE MANIFOLD AND ATTACHMENTS OVERVIEW .

-- Tighten the high pressure line union nuts by hand.

-- Make sure the high pressure line is free of tension.

-- Use torque wrench (5-50 Nm) V.A.G 1331 with ratchet, reversible V.A.G 1331/1 and the socket T40055 to tighten the high pressure line.

Fig 7: Identifying Socket T40055 At particles To Torque Wrench (5-50 Nm) V.A.G 1331 To Tighten Union Nuts

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Tightening Specifications 

• FUEL RAIL AND INJECTORS OVERVIEW 
• INTAKE MANIFOLD AND ATTACHMENTS OVERVIEW 

-- Fill the fuel system. Refer to FUEL SYSTEM, FILLING AND BLEEDING .