Removal and Replacement
Removing And Installing Intake-air Distributor
Tools
Preliminary work
Preliminary work for removing intake distributor
1. Move bonnet to service position using bonnet stay 9704.
2. Disconnect battery.
3. Put on the protection covers.
4. Pull the design cover up and off.
5. Remove engine compartment covers.
6. Remove connector tube from air cleaner to engine. To do this, loosen the hose clamp on the engine, unplug the electric connector on the hot-film mass air flow meter and remove the two fastening pins on the air cleaner cover -arrows-.
7. Remove the vacuum line on the throttle body from the connector tube. Then take the intake manifold out of the engine compartment.
8. Remove cover of air cleaner housing by loosening the clamps -arrows- and pulling off the cover.
9. Separate the six ignition coils from the wiring loom. To do this, press the connectors slightly downwards -arrow A-, release them using a suitable auxiliary tool (e.g. an angled wire) -arrow B- and remove them -arrow C-.
Component overview
NOTE: Please read the most important working regulations and warning notes.
Removing intake-air distributor
1. Release wiring harness to the left and right on the intake distributor. To do this, remove cable clips -arrows- carefully with a small screwdriver and release cable.
2. Pull off cable plug on the throttle adjuster and pull cable out of the clip -arrows-.
3. Disconnect positive crankcase ventilation plug on cylinder head cover -1-.
4. Press in plastic connectors on the flange and pull off wires -3 and 4-.
5. Unscrew fastening screw for vacuum unit (M6 x 20. hexagon socket) -2- and remove vacuum unit.
6. Pull off cable plug on vacuum flange of intake-air distributor -arrows-.
7. Press in plastic connectors on the vacuum flange and pull off wires -arrows-.
8. Lay plastic lines aside.
9. Unscrew three M8 hexagon socket head bolts on exhaust side -arrows- (two at the side and one fastening screw on centre of heat shield).
10. Pull off the vacuum line on the vacuum modulator on the inlet side. To do this, press on the connector.
11. Unscrew two M6 nuts -1 and 2- from vacuum unit holder. Pull out oil dip stick and remove vacuum unit from its rubber mounts and set it aside.
NOTE: A mirror is very useful when screwing out the fastening screws on the intake distributor.
12. Unscrew all nine hexagon socket head bolts (M7 x 40) on the inlet side of the intake distributor.
13. First raise the intake distributor on the exhaust side and then lift it off on the inlet side.
14. Cover the openings of the cylinder head with a cloth so that nothing can fall into it.
15. Remove intake distributor seal as well as the seal from the dowel sleeves.
Installing intake-air distributor
NOTE: The intake-air distributor seal must always be replaced.
1. Clean sealing surfaces and insert new seal into the intake distributor. Make sure that the dowel sleeves of the fastening screws are seated correctly in the seal.
NOTE: Make sure that the vacuum unit and the oil dip stick tube do not hinder the installation of the intake-air distributor.
2. First position the intake distributor on the inlet side and then press it down on the exhaust side.
NOTE: A mirror is very useful for inserting the fastening screws on the intake distributor.
3. Insert all nine hexagon socket head fastening screws (M7 x 40) into the intake distributor on the inlet side. Ensure that all screw holes are positioned correctly in front of their fastening points and that no components (e.g. wires) are jammed.
4. Tighten all nine hexagon socket head fastening screws (M7 x 40) on the inlet side. Tightening torque: 9.5 ftlb.
5. Fit vacuum unit into rubber mounts. Insert dipstick tube into the crankcase bore, while checking that the sealing ring on the tube is positioned correctly in the bore. Insert dipstick. Move dipstick tube into installation position and screw in two M6 nuts -1 and 2-into the vacuum unit support. Tightening torque: 7.5 ftlb.
6. Insert vacuum line into the vacuum unit on the inlet side.
7. Fit three M8 hexagon socket head bolts on exhaust side -arrows-(two at the side and one fastening screw on centre of heat shield). Tightening torque: 17 ftlb.
8. Move vacuum lines into installation position.
9. Connect plastic connectors of vacuum lines to the flanges of the intake distributor -arrows-.
10. Connect cable plug on intake-air distributor flange -arrows-.
11. Connect positive crankcase ventilation plug on cylinder head cover -1-.
12. Press in plastic connectors on the flange and fit wires -3 and 4-.
13. Move vacuum unit into installation position and fit vacuum unit fastening screw (M6 x 20 hexagon socket head bolt) -2- to 7.5 ftlb. Tightening torque: 7.5 ftlb.
14. Attach cable plugs and cable to throttle adjuster -arrows-.
15. Fit wiring harness to the left and right on the intake distributor. To do this, fasten the cable clips -arrows-.
Subsequent work
Subsequent work for installing intake distributor
1. Re-connect ignition coil plugs to the ignition coils.
2. Install cover of air cleaner housing by clipping in the clamps -arrows-.
3. Fit connector tube from air cleaner to engine. To do this, fasten the hose clamp on the engine, connect the electric connector on the hot-film mass air flow meter and insert the two fastening bolts on the air cleaner cover -arrows-.
4. Then move the intake manifold to installation position. Connect vacuum line on throttle body to the connector tube.
5. Press the design cover back on to the ball heads.
6. Mount engine compartment covers.
7. Remove protective covers, connect battery and fasten bonnet.