1.4 TSI engine (EA111) · Mixture preparation – injection · Intake manifold

Intake manifold – assembly overview and fastening

Part I

1 Intake air temperature sender 3 - G520- with intake manifold pressure sender 3 - G583-
2 3 Nm
3 7 Nm
- Self-tapping bolt
- The securing bolt may only be tightened using an impact wrench if the wrench speed is max. 500 rpm and a max. specified torque of 7 Nm is set.
4 Intake connecting pipe
5 Seal
- Renew
- Before installing, lightly coat seal with clean engine oil.
6 Regulating flap control unit - J808-
- Removing and installing ⇒ 2.2 Removing and installing regulating flap control unit - J808- and throttle valve module - J338-

7 7 Nm
- Self-tapping bolt
- The securing bolt may only be tightened using an impact wrench if the wrench speed is max. 500 rpm and a max. specified torque of 7 Nm is set.
8 Intake connecting pipe
9 Intake manifold connection
10 7 Nm
- Self-tapping bolt
- The securing bolt may only be tightened using an impact wrench if the wrench speed is max. 500 rpm and a max. specified torque of 7 Nm is set.
11 3 Nm
12 Intake manifold pressure sender - G71-
13 O-ring
- Renew
14 Intake manifold

15 20 Nm
16 Fuel pressure sender - G247-, 22 Nm
- Checking fuel pressure in high-pressure section ⇒ 4.1 Checking fuel pressure sender.
17 80 Nm
18 Intake manifold lower part

Reason: After removing injector, Teflon seal and support washer must be renewed ⇒ 3.3 Renewing seals on injectors.

To remove and install: using "bracket for bits 5/16""" - V.A.G 1766/2- and Bit - 3320/2- ⇒ 2.1 Assembly overview - intake manifold
To remove, removing and installing regulating flap control unit - J808-, throttle valve module - J338- and intake manifold ⇒ 2.2 Removing and installing regulating flap control unit - J808- and throttle valve module - J338-.

19 Seal
- Renew
- Observe installation position
20 20 Nm
21 Throttle valve module - J338-
- Removing and installing ⇒ 2.2 Removing and installing regulating flap control unit - J808- and throttle valve module - J338-
- Cleaning ⇒ 2.3 Cleaning throttle valve module - J338-
- If renewed, erase learnt values and adapt engine control unit - J623- ⇒ Vehicle diagnostic tester “Guided functions”.
22 7 Nm
23 Pressure pipe
- From turbocharger
24 Retaining clip
25 7 Nm

Removing and installing lower part of intake manifold

To remove and install securing bolt -arrow-, use holder for bits with 5/16'' drive - V.A.G 1766/2- and special wrench, long reach - 3320/2-.

Removing

Push pin -1- in direction of -arrow- until hold-down device is securely seated on injectors.
Tighten knurled nuts -1- and -2- hand-tight.
Pull lower part of intake manifold evenly off injectors.

Installing

Part II

1 Union
- For fuel supply.
2 Fuel hose
- For fuel supply.
- Low pressure
- To high-pressure pump
3 Clamp
4 Connection hose
- To activated charcoal filter solenoid valve 1 - N80-
5 Activated charcoal filter solenoid valve 1 - N80-
6 Connection hose
7 To pressure pipe.
8 Connecting pipe
9 Connection hose
- To intake manifold connection.
10 8 Nm
11 Fuel line
- High pressure
- Specified torque for union nuts: 18 Nm.
12 Union
- To intake connecting pipe.
13 Connection hose
14 Non-return valve
- For crankcase ventilation.
- Specified torque: 10 Nm
15 Connection hose
16 Charge pressure control solenoid valve - N75-
17 Connection hose
18 Connection hose
- To turbocharger
19 Union
20 5 Nm
21 Connection hose
- To turbocharger
22 Union
23 Union
- For crankcase ventilation.
24 Connection hose
- For crankcase ventilation.
25 Connection hose
- To charge pressure control solenoid valve - N75-.
26 Union
- For crankcase ventilation.
- Connected to valve timing housing.
- Specified torque: 10 Nm