Removal and Replacement

Removing And Installing Intake Distributors - Engine Installed

WARNING: Observe the general safety instructions when working on the fuel system and when handling petrol and other fuels.

- Emerging fuel when fuel line is disconnected.
- Smoking, fire and naked flames are forbidden.







- Attaching warning sign to vehicle in a clearly visible position. (see figure)

CAUTION:
- Pentosin is hazardous to health.
- Wear protective gloves and goggles. If the eyes or skin come into contact with the fluid, wash immediately with water.
- Collect emerging Pentosin.
- Protect the lines against soiling and damage with caps.
- Clean hoses which come into contact with Pentosin thoroughly.
- Danger of scalding when the engine is hot; coolant is under pressure. Do not begin working until the engine has cooled down.
- Carefully open the cap on the expansion tank.
- Coolant is hazardous to the health and irritates the skin.
- When handling coolant, wear protective gloves and goggles.
- In case of contact with the skin or eyes, wash immediately with plenty of water.

Component overview










Removing intake distributor
1. Disconnect the battery.
2. Remove air cleaner housing.
3. In vehicles with air conditioning, the following work operations must be performed:







- a. Remove the drive belt from the belt pulley of the air conditioning compressor. Mark the running direction of the belt with a coloured pen. Slacken belt by turning the tensioning pulley (a/f 24) clockwise, hold still and simultaneously take the drive belt off the belt pulley of the air-conditioning compressor. Carefully allow the tensioning roller to turn back into tensioning position.







- b. Disconnect battery positive lead -1- at B+ disconnection point. Unscrew the hexagon nut M8 and remove the positive lead. Then unscrew the hexagon-head bolt M6 x 12 -2- at the holder and lay the holder and box to one side.







- c. Extract Pentosin fluid from the servo-tank with a pump. Dispose of extracted Pentosin according to the relevant regulations. Lay a cloth under the tank to collect any emerging Pentosin. Open the bayonet lock anti-clockwise and remove the tank. Immediately seal the lower tank opening with a plug (approx. 30 mm).

INFORMATION: After removal, place the air-conditioning compressor on a suitable protective support (e.g. foam, neoprene, etc.).










- d. Remove the air-conditioning compressor. Tool recommendation: 1/4 inch -Figure 2/d3-. 3 hexagon-head bolts M8: Unscrew 2 bolts at rear -1-, 1 at front -2-. For better access to the front threaded part -2-, remove the engine compartment temperature sensor with the rubber sleeve at the right intake distributor. Remove the aluminium spacer sleeve. Disconnect the ground cable at the plug connection.







- e. Lift out the air-conditioning compressor with the lines connected and lay to one side on a protective support. Also secure against falling down (tie wraps).

4. Remove hose to the secondary pump -4-.
5. Slowly open the cap of the coolant expansion tank and relieve the pressure in the cooling system. The release the spring band clamp of the top coolant hose -1- and pull the hose off. Collect the draining coolant.
6. Unscrew the holder of the vacuum line (to the brake booster) on the left intake distributor (Tiptronic only). To do this, unscrew an M6 hexagon-head bolt and separate the pipe connector -3-. To do this, push the plastic clip out using a small screwdriver and pull the line apart.

INFORMATION: In order to avoid damaging hoses and lines, lower the engine by no more than 40 mm.







7. Lower the engine by 30 - 40 mm. To do this, support the engine with a jack and unscrew the two M12 collar nuts (a/f 18) of the rear engine mounts. Pay attention to hose and line connections.
8. Disconnect plug connection of the fuel line -1-. Unclip the plastic clip of the fuel line on the coolant expansion tank. Collect emerging fuel with a cloth.
9. Remove cable plug of the coolant level sensor -5-.
10. Remove cable plug and vacuum hoses of the electrical switch-over valve -6- above the generator.







11. Remove throttle housing.
12. Press together the plug connection on top and bottom of the central intake distributor -3- and pull out the pipe.
13. Disengage switch-over valve of the tank ventilation -4- from the plastic clip and pull off cable plug.







14. Remove coolant hose -arrow- by undoing the spring-band clamp and then pulling off the hose.
15. Unclip the line assembly (bleed line, fuel line, vacuum line to the brake booster) from the plastic holder on the body and lay it aside.
16. Pull engine compartment temperature sensor out of the holder on the right intake distributor (cylinder bank 4 - 6).







17. Undo four screw-type hose clamps -2 and 3- on the right intake side.







18. Unscrew M6 x 35 hexagon-head bolts -arrows- of the intake distributor for cylinder bank 4 - 6 and push the intake distributor out of the rubber sleeves towards the right.
19. Remove rubber sleeves from centre air distributor and tuning pipe. Carefully remove right intake distributor. Immediately plug or cover the intake manifold.







20. Undo the outer left screw-type hose clamps of the centre intake distributor and of the tuning pipe -2 and 3-. Remove centre intake distributor and tuning pipe. Remove vacuum hose and vacuum unit on the tuning pipe.
21. Remove intake distributor for cylinder bank 1 - 3 by unscrewing six M6 x 35 hexagon-head bolts. Use a small offset ring wrench (wrench size 10) for the front bolt. Remove intake distributor together with the front screw. Immediately plug or cover the intake manifold.

Installing intake distributor

INFORMATION:
- Micro-encapsulated screws must be replaced.
- Replace all seals on the intake distributor.
- Clean sealing faces with a clean cloth soaked in solvent naphtha or acetone. Wear protective gloves.







1. Place the intake distributor 4 - 6 with new seals and inserted front screw on the intake manifold, then affix the M6 x 35 hexagon head bolts. Screw in the front screw using a small offset ring wrench (wrench size 10). Tighten the screws.

Tightening torque 10 Nm (7.5 ftlb.)

INFORMATION: Align the marking arrow on the tuning pipe with the intake distributor.

2. Fit the rubber sleeves with screw-type hose clamps on the tuning pipe and centre intake distributor (do not tighten the screw-type hose clamps yet). Push vacuum hose onto the vacuum unit on the tuning pipe and push the tuning pipe with rubber sleeve onto the intake distributor 1 - 3. Also push the centre intake distributor onto the intake distributor 1 - 3. Do not tighten the screw-type hose clamps yet.
3. Place intake distributor 4 - 6 onto the intake manifold and push it into the rubber sleeves of the centre intake distributor and the tuning pipe. The tuning pipe has an arrow marking for positioning on the intake distributor. Affix and tighten the M6 x 35 hexagon-head bolts of the right intake distributor.

Tightening torque 10 Nm (7.5 ftlb.)

4. Position the throttle housing on the centre intake distributor and fix it in place with 3 M6 hexagon-head bolts. Fasten the retaining bracket on the throttle parts with the lower left screw. Push on cable plug and clip in cable. Align the centre intake distributor and tighten all screw-type hose clamps and screws.

Tightening torque for M6 hexagon-head bolts 10 Nm (7.5 ftlb.)







5. Fit bleed line onto connecting piece of the centre intake distributor -3-. Clip switch-over valve of the tank ventilation -4- into the cable holder and connect cable plug.
6. Insert engine compartment temperature sensor into the holder on the right intake distributor.










7. Connect vacuum hoses and cable plugs on the switch-over valve -6-.
8. Fasten hose holder (Tiptronic only) on the left intake distributor. To do this, tighten the M6 hexagon-head screw and push on the pipe connector of the vacuum line to the brake booster -3-. Then press the plastic clip in and secure the line.

Tightening torque for the M6 hexagon-head bolt 10 Nm (7.5 ftlb.)

9. Push top coolant hose -1- onto the filler neck of the coolant expansion tank, then fasten the spring-band clamp.
10. Then push on hose of the secondary-air pump -4- again.







11. Fit coolant hose -arrow-. To do this push on the coolant hose and fasten the spring-band clamp with a set of spring-band clamp pliers.







12. Raise the engine with the jack and then tighten the two M12 collar nuts (a/f 18) on the rear engine mounts.

Tightening torque 85 Nm (63 ftlb.)

13. Connect plug connection of the fuel line -1-. Fit fuel line and plastic holder on the coolant expansion tank.
14. Push on cable plug of the coolant level sensor -5-.
15. Install the air-conditioning compressor. To do this, fit the aluminium spacer sleeve and tighten three M8 hexagon-head bolts. Connect the ground cable at the plug connection.
15. Install the air-conditioning compressor. To do this, fit the aluminium spacer sleeve and tighten three M8 hexagon-head bolts. Connect the ground cable at the plug connection.
16. Install air cleaner housing.
17. Check the coolant level.
18. Connect the battery.

Tightening torques