2007 Volkswagen Touareg (7LA) V6-3.6L (BHK)

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1 Page 1 of Volkswagen Touareg (7LA) V6-3.6L (BHK) Vehicle» Engine, Cooling and Exhaust» Engine» Intake Manifold» Service and Repair» Intake Manifold Intake Manifold Special tools, testers and auxiliary items required Torque wrench (VAG 1331) Puller (T10095 A) Multi point socket (T10347) Removing Read safety precautions before beginning work. Refer to --> [ Safety Precautions ] See: Powertrain Management\Fuel Delivery and Air Induction\Service Precautions\Vehicle Damage Warnings\Safety Precautions. Observe the rules for cleanliness. Refer to --> [ Clean Working Conditions ] See: Powertrain Management\Fuel Delivery and Air Induction\Service Precautions\Vehicle Damage Warnings\Clean Working Conditions. If a fuel injector is removed, Teflon sealing ring of combustion chamber as well as O-ring must always be replaced. Refer to --> [ Fuel Injector Teflon Seal and Support Washer ] See: Powertrain Management\Fuel Delivery and Air Induction\Fuel Injector\Service and Repair\Fuel Injector Teflon Seal and Support Washer. Sealing ring --> [ (Item 1) Seal ] See: Powertrain Management\Fuel Delivery and Air Induction\Fuel Pump\Service and Repair\Fuel Rail with High Pressure Pump and Injectors Assembly Overview must also be replaced at fuel injectors for cylinders 1, 3 and 5. If fuel rail is removed, spring retainers for fuel injectors - arrow - must be replaced.

2 Page 2 of 11 Fuel rail with high pressure pump and fuel injectors assembly overview. Refer to --> [ Fuel Rail with High Pressure Pump and Injectors Assembly Overview ] See: Powertrain Management\Fuel Delivery and Air Induction\Fuel Pump\Service and Repair\Fuel Rail with High Pressure Pump and Injectors Assembly Overview. Intake manifold assembly overview. Refer to --> [ Intake Manifold Assembly Overview ] See: Intake Manifold Assembly Overview. CAUTION! When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues: Route lines of all types (e.g. for fuel, hydraulic, Evaporative Emission (EVAP) system, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed. To prevent damages to the lines, make sure there is sufficient clearance to all moving or hot components. CAUTION! Follow safety measures for releasing fuel pressure on high pressure side. Refer to --> [ Releasing Pressure on High Pressure Side ] See: Fuel Pressure Release\Service and Repair. Disconnect battery ground (GND) cable with ignition switched off.

3 Page 3 of 11 Drain the cooling system. Refer to --> [ Draining and Filling ] See: Cooling System\Service and Repair\Procedures. Remove coolant hoses and Remove bolt from oil dipstick guide tube Remove guide tube with oil dipstick. Remove ribbed belt. Refer to --> [ Ribbed Belt ] See: Drive Belt\Service and Repair\Ribbed Belt Remove ribbed belt tensioner --> [ (Item 25) Tensioning element ] See: Cylinder Head Assembly\Service and Repair\Cylinder Head Assembly Overview. Remove generator.. Remove coolant hoses from coolant pipe

4 Page 4 of 11 Remove vacuum hoses from Intake Manifold Runner Control (IMRC) valve (N316) - arrows -. Loosen bolts from coolant pipe approximately 1 turn. Remove bolts and remove coolant pipe from intake manifold. Remove connecting hose to throttle valve control module (J338). Refer to --> [ Air Filter Assembly Overview ] See: Air Cleaner Housing\Service and Repair. Disconnect harness connector from throttle valve control module (J338). Disconnect harness connectors from ignition coil with power output stage (N70, N127, N291, N292, N323, N324).

5 Page 5 of 11 Remove ignition coils with power output stage. Refer to --> [ Ignition Coils with Power Output Stages ] See: Powertrain Management\Ignition System\Ignition Coil\Service and Repair\Ignition Coils with Power Output Stages. Remove wiring harness of ignition coils with power output stage from intake manifold. CAUTION! Fuel supply lines are under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before loosening the fuel lines, place a cloth around the connection point. Then release pressure by carefully loosening the union nuts. Lay a cloth around threaded connection and loosen union nut - arrow - from fuel supply hose. To do so, counter hold on fuel supply line using a wrench. Disconnect high pressure line as well as low pressure line from high pressure pump. When doing this, counter hold on connection of high pressure pump using a wrench.

6 Page 6 of 11 Disconnect harness connectors - arrows -. Remove bolts --> [ (Item 15) 10 Nm ] See: Powertrain Management\Fuel Delivery and Air Induction\Fuel Pump\Service and Repair\Fuel Rail with High Pressure Pump and Injectors Assembly Overview of high pressure pump and remove high pressure pump. Remove fuel rail connecting line - arrows -. Disconnect the connecting hose for the crankcase ventilation from the cylinder head cover.

7 Page 7 of 11 Remove rear intake manifold support bolt - arrow -. Remove front intake manifold support bolt - arrow -. Disconnect lines - arrows - from intake manifold.

8 Page 8 of 11 Remove right intake manifold support bolt Remove bolts for intake manifold/cylinder head --> [ (Item 1) 8 Nm ] See: Intake Manifold Assembly Overview. Remove bolts of fuel rail for cylinders 2, 4 and 6 - arrows -. Carefully pull off fuel rail from fuel injectors. Remove intake manifold downward and set it down on a suitable surface.

9 Page 9 of 11 Seal the intake channels in intake manifold and in cylinder head using clean cloths. Installing Installation is performed in the reverse order of removal, noting the following: Replace O-rings between fuel injectors and fuel rail and coat them lightly with clean motor oil. Replace spring retainers - arrow - at all fuel injectors. Install intake manifold. Place fuel rail on and press evenly onto fuel injectors. Insert all bolts of intake manifold and of fuel rail by hand. First evenly tighten fuel rail to cylinder head with new bolts from inside to outside. Tighten intake manifold/cylinder head bolts. Then tighten bolts on intake manifold support. Install fuel rail connecting line - arrows -.

10 Page 10 of 11 Tighten union nuts of connecting line first by hand and then tighten to specifications. Check plunger --> [ (Item 17) Lifter ] See: Powertrain Management\Fuel Delivery and Air Induction\Fuel Pump\Service and Repair\Fuel Rail with High Pressure Pump and Injectors Assembly Overview for damage, replace if necessary. Insert oiled lifter with guide perpendicularly into cylinder head.

11 Page 11 of 11 Rotate engine at vibration damper slowly in direction of engine rotation. When doing this, press plunger in - direction of arrow - until it reaches the deepest point in cylinder head. Install high pressure pump. O-ring of high pressure pump must always be replaced. Before installing fuel lines, first tighten connection for fuel lines on high pressure pump. Connection for high pressure line: 40 Nm Connection for low pressure line: 28 Nm Tighten union nuts of fuel lines first by hand and then tighten to specifications. Install ribbed belt tensioner. Install ribbed belt. Refer to --> [ Ribbed Belt ] See: Drive Belt\Service and Repair\Ribbed Belt. Fill cooling system. Refer to --> [ Draining and Filling ] See: Cooling System\Service and Repair\Procedures. Replace

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