Intake Manifold: Service and Repair

Removing And Installing Intake-Air Distributor

Technical values







Preliminary work

Preliminary work for removing intake distributor

1. Remove design cover. Removing and Installing Engine Cover (Design Cover)

Information

Component overview













Removing intake-air distributor

INFORMATION:
- Absorb any escaping fuel using a suitable binding material or a cloth.
- Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
- The fuel system must be depressurised before starting work on it.
- Only work on the fuel system in well-ventilated rooms.
- Any seals which have been removed must always be replaced.
- Do not use any sealant containing silicone or silicone spray when the injection system is open. Traces of silicone drawn in by the engine are not combusted and damage the oxygen sensors.







1. Separate the electric connection from the throttle adjuster. To do this, press on the plug at the top and bottom and, at the same time, pull it off. Unclip the cable from the sheetmetal holder.

CAUTION:
Risk of damaging the fastening bolts.
- The fastening bolts will break if they are turned in the wrong direction.

- Only turn the fastening bolts in the correct direction of rotation for opening and closing.







2. Release the fastening bolts on the throttle body. To do this, twist the right and left pin through 45 degrees in an anti-clockwise direction.







3. Remove the fastening bolts. To do this, take hold of the bolt by the rubber ring with pliers and pull it out.
4. Pull off the Y-shaped pipe from the throttle body.







5. Disconnect the air flow sensor connections. To do this, undo the hose clamps to the left and right on the bellows and pull the bellows off the air flow sensors.







6. Remove the vacuum line on the Y-shaped pipe. To do this, press the button and disconnect the vacuum line.







7. Disconnect the vacuum line on the rear of the intake system.










8. Disconnect positive crankcase ventilation line on the two valve covers. To do this press the plastic ring and pull the connections. Then remove the positive crankcase ventilation line from the retaining clip.







9. Then remove the line between the oil mist collector and the intake distributor.

DANGER: Danger of fire from fuel.

- Keep clear of ignition sources.
- Do not smoke.
- Disconnect battery.
- Danger of fire due to naked flames and sparks, e.g. during welding or grinding work.
- Danger of fire due to escaping fuel, e.g. on hot engine components or due to electrostatic charge. Allow engine to cool down.
- Secure the vehicle, e.g. with a warning sign.
- Change any clothing soaked with fuel immediately.
- In case of fire, use CO2 or dry powder fire extinguishers.

DANGER: Danger of poisoning from fuels.

- Gasoline is toxic.
- Inhaling vapours can cause irritation of the mucous membranes and eyes.
- It can be carcinogenic. It represents a serious risk to health when inhaled, touched or swallowed over longer periods.
- Only work on the fuel system in well-ventilated rooms.
- Wear protective gloves that are fuel-resistant.
- Wear a breathing mask with active charcoal filter; do not breathe in any fuel vapours.
- Ensure that there is adequate ventilation and extract all fuel vapours.
- Before opening the fuel lines or fuel hoses, relieve the fuel pressure.
- Collect escaping fuel, absorb it if necessary with a suitable binding material and dispose of properly.
- Pay attention to cleanliness when working on the fuel system.

INFORMATION:
- Before the lines are opened, place a cloth or a suitable container underneath them.
- Collect escaping fuel.







10. Disconnect fuel line -1- and line -2- to the carbon canister on the radiator tank splash panel.







11. Disconnect the electric connectors to the eight fuel injectors. To do this, press the metal clip on the plug and pull off the plug.







12. Unscrew the fastening screws on the intake distributor in the sequence shown below.
13. Remove intake distributor from the engine in an upward direction.

Installing intake-air distributor

INFORMATION:
- Absorb any escaping fuel using a suitable binding material or a cloth.
- Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
- The fuel system must be depressurised before starting work on it.
- Only work on the fuel system in well-ventilated rooms.
- Any seals which have been removed must always be replaced.
- Do not use any sealant containing silicone or silicone spray when the injection system is open. Traces of silicone drawn in by the engine are not combusted and damage the oxygen sensors.







1. Replace intake distributor gaskets.







2. Place intake-air distributor on the engine and tighten the screws in the sequence shown below. - Tightening sequence for suction module - Initial tightening: 7.5 ftlb. - Final tightening: 11 ftlb.







3. Connect the 8 electric connectors to the injection valves. The connectors must engage audibly.







4. Install positive crankcase ventilation line. The 2 connections must audibly engage. Then close the mounting clip.







5. Install line between intake distributor and oil mist collector.

DANGER: Danger of poisoning from fuels.

- Gasoline is toxic.
- Inhaling vapours can cause irritation of the mucous membranes and eyes.
- It can be carcinogenic. It represents a serious risk to health when inhaled, touched or swallowed over longer periods.
- Only work on the fuel system in well-ventilated rooms.
- Wear protective gloves that are fuel-resistant.
- Wear a breathing mask with active charcoal filter; do not breathe in any fuel vapours.
- Ensure that there is adequate ventilation and extract all fuel vapours.
- Before opening the fuel lines or fuel hoses, relieve the fuel pressure.
- Collect escaping fuel, absorb it if necessary with a suitable binding material and dispose of properly.
- Pay attention to cleanliness when working on the fuel system.

DANGER: Danger of fire from fuel.

- Keep clear of ignition sources.
- Do not smoke.
- Disconnect battery.
- Danger of fire due to naked flames and sparks, e.g. during welding or grinding work.
- Danger of fire due to escaping fuel, e.g. on hot engine components or due to electrostatic charge. Allow engine to cool down.
- Secure the vehicle, e.g. with a warning sign.
- Change any clothing soaked with fuel immediately.
- In case of fire, use CO2 or dry powder fire extinguishers.







6. Connect fuel line -1- and line -2- from the carbon canister on the radiator tank splash panel.







7. Connect vacuum line to the rear of the intake distributor. The plug must engage audibly.







8. Attach the vacuum line to the underside of the Y-shaped pipe.







9. Slide the bellows onto the air flow sensors and tighten the hose clamps.

CAUTION:
Risk of damaging the fastening bolts.
- The fastening bolts will break if they are turned in the wrong direction.

- Only turn the fastening bolts in the correct direction of rotation for opening and closing.







10. Slide the Y-shaped pipe onto the throttle adjuster. Then insert the left and right fastening bolts. Turn the right and left bolts 45 degrees clockwise.







11. Connect the throttle adjuster. The connector must engage audibly. Clip the connecting cable into the sheetmetal holder.

Subsequent work

Subsequent work for installing intake distributor
1. Install design cover