Removing and installing lower part of intake manifold with fuel rail — VW

🧭 Before you start

Fits: VW Passat B6 (3C, 2005–2010)

• Renewed: o-rings between injector

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• If an injector was pulled out of the cylinder head, the Teflon seal must be renewed .Seal intake ports in cylinder head with a clean cloth.
• Tighten fuel rail securing bolts on cylinder head evenly from inside to outside.Then tighten securing bolts for intake manifold lower part/cylinder head.
• First tighten union nuts for connection pipe hand tight, then tighten to specified torque.

🔧 Engine codes this applies to

📐 5 workshop diagrams for BWS

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. ⚠ Observe safety precautions when releasing fuel pressure in high-pressure section — Disconnect earth strap at battery with ignition switched off Electrical system27Disconnecting and reconnecting battery.
2. Remove noise insulation General body repairs, exterior50Noise insulation.
3. Remove intake manifold upper part .
4. Remove high-pressure pump.
5. Remove connecting pipe of fuel rail (arrows).

6. Unscrew securing bolts for intake manifold lower part/cylinder head (arrows).
7. Unscrew securing bolt from oil dipstick guide tube (1).
8. Remove bracket (2) from intake manifold lower part.
9. Undo bolts of fuel rail for cylinders 2, 4, and 6 (arrows).
10. Carefully pull fuel rail off injectors.
11. Remove lower part of intake manifold. [Note: If an injector was pulled out of the cylinder head, the Teflon seal must be renewed .Seal intake ports in cylinder head with a clean cloth.]
12. Renew O-rings between injector and fuel rail and moisten slightly with clean engine oil.
13. Renew spring elements (arrow) of all injectors.
14. Fit lower part of intake manifold with a new gasket.
15. Set fuel rail and evenly press onto injectors.
16. Fit all intake manifold and fuel rail securing bolts by hand. [Note: Tighten fuel rail securing bolts on cylinder head evenly from inside to outside.Then tighten securing bolts for intake manifold lower part/cylinder head.]
17. Install connecting pipe of fuel rail.
18. Installing high-pressure pump . [Note: First tighten union nuts for connection pipe hand tight, then tighten to specified torque.]
19. Install upper part of intake manifold .

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