ALLDATA Online - 2007 Volkswagen GTI L4-2.0L Turbo (BPY) - Intake Manifold, Removing and Ins...

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2007 Volkswagen GTI L4-2.0L Turbo (BPY) Vehicle Level Engine, Cooling and Exhaust Removing and Installing Engine Intake Manifold Service and Repair Intake Manifold,

Intake Manifold, Removing and Installing

Notes

Intake Manifold, Removing And Installing Removing: CAUTION: Follow safety measures for releasing fuel pressure in high pressure area. NOTE: Observe the rules for cleanliness If a fuel injector was pulled out of cylinder head when removing the intake manifold, the Teflon sealing ring must be replaced. Intake manifold, assembly overview. Remove Throttle Valve Control Module J338. Disconnect all electrical harness connectors necessary. Disconnect vacuum hose between intake manifold and vacuum pump from intake manifold. CAUTION: Fuel supply line is under pressure. Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

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Disconnect wires - 1, 2 and 3 -. To do so, press release buttons.

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ALLDATA Online - 2007 Volkswagen GTI L4-2.0L Turbo (BPY) - Intake Manifold, Removing and Ins... Page 2 of 4

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Disconnect vacuum lines -arrows- from intake manifold and from cylinder head cover. CAUTION: Fuel lines are under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before loosening the fuel line, place a rag around the connection point. Then release pressure by carefully loosening.

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Disconnect both fuel lines from high pressure pump.

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Disconnect coolant pipe and oil dipstick guide from intake manifold -arrows- and pull off oil dipstick guide upward from engine.

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Remove intake manifold support -arrows- and disconnect connector -1- from Fuel Pressure Sensor G247. Remove all bolts from intake manifold. Carefully pull off intake manifold with fuel rail from cylinder head. Installing: Installation is in reverse order of removal, note the following: If a fuel injector was pulled out of cylinder head when removing intake manifold, replace Teflon sealing ring of fuel injector. Replace O-rings between fuel injectors and fuel rail and coat them lightly with clean motor oil. Position intake manifold with fuel rail on cylinder head and press evenly onto fuel injectors. If Intake Flap Motor V157 or intake manifold was replaced, Intake Manifold Runner Position Sensor G336 must be adapted to ECM "Guided Functions". Torque specifications Mounting bolts for intake manifold Bolt for intake manifold support Nut for intake manifold support Nm 10 23 10

Fuel supply line to high pressure pump 25 Fuel return line to high pressure pump (replace banjo fitting) Bolts for Intake Flap Motor V157 7 17

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