Intake Manifold

WARNING: This page is about a different car, the 2014 Volkswagen Jetta, 2013 Volkswagen Jetta, 2012 Volkswagen Jetta, and 2011 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Socket - Xzn 10T10385
Socket - Xzn 8T40159
Torque Wrench 1331 5-50 Nm VAG 1331
Hose Clip Pliers VAS 6362
Torque Wrench 1331 Insert - Reversible Ratchet VAG 1331/1
Engine Bung Set VAS 6122

CAUTION:

Follow the safety precautions when working on the diesel direct injection system. Refer to SAFETY PRECAUTIONS .
Observe the rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .

Always follow these instructions before and during work.

Removing

NOTE:

Make sure no contaminants enter the fuel system when removing the intake manifold.

Seal off the connections in the fuel system using plugs from the Engine Bung Set VAS 6122.

-- 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 Differential Pressure Sensor -G505- connector -B- and the Fuel Pressure Sensor -G247- connector -C-.

Fig 2: Disconnecting Fuel Injector Connectors

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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.

CAUTION:

Always follow the procedure "Glow Plug Connector, Disconnecting and Connecting".

-- 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 Clamp

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-- 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 in the -direction of arrow- to release them.

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

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NOTE:

Maintain clean working conditions. Dirt and contaminants must not enter the return lines and the connections on the fuel injectors.

-- 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 Fuel Temperature Sensor -G81- Connector -1-, Fuel Metering Valve -N290- Connector -2- And Spring Clamps -3 / 4-

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-- Seal the lines so that the fuel system is not contaminated by dirt or contaminants.

-- Remove the fuel return lines.

-- Disconnect the EGR Vacuum Regulator Solenoid Valve -N18- connector -1- and the Throttle Valve Control Module -GX3- connector -3-.

Fig 6: Identifying Connectors

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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-.

CAUTION:

Make sure the connecting pipe coupling element does not bend or stretch. Cracks could develop.

-- Remove bolts -1- and -2- and remove the Throttle Valve Control Module -J338- and bracket.

Fig 7: Identifying Intake Manifold Bolts

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

-- Remove the intake manifold.

Installing

Install in the reverse order of removal. 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 line 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, refer to -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 1331 5-50 Nm VAG 1331 with Torque Wrench 1331 Insert - Reversible Ratchet VAG 1331/1 and the Union Nut Socket T40055 to tighten the high pressure line.

Fig 8: 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

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Tightening Specifications

Refer to FUEL RAIL AND INJECTORS OVERVIEW
Refer to INTAKE MANIFOLD AND ATTACHMENTS OVERVIEW

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