Intake Air Plenum: Service and Repair
Removing And Installing Intake Distributor
No. I - 7:
Removing intake distributor
WARNING:
Risk of damage
- The mounting bolts will break if they are turned in the wrong direction.
1. Pull the throttle body cover vertically upwards.
2. Separate the electrical connection from the throttle positioner. To do this press the top and bottom of the connector while pulling. Unclip the cable from the sheet metal support.
3. Unlock the retaining bolts on the throttle body. To do this turn the right bolt 45 degrees anti-clockwise and the left bolt 45 degrees clockwise.
4. Remove the retaining bolts. To do this take hold of the bolt on the rubber ring with pliers and pull it out.
5. Remove the Y pipe from the throttle body.
6. Separate the air flow sensors. To do this release the hose clamps on the left and right of the bellows and remove the bellows from the air flow sensors.
7. Remove the vacuum line on the Y pipe. To do this press the button and remove the vacuum line.
8. Disconnect the vacuum line on the rear of the intake system.
9. Remove engine compartment cover on the right side. To do this unscrew the 4 bayonet screws and the fastening screw on the windshield washer reservoir.
10. Unscrew the torque support. To do this unscrew the fastening screw on the torque support bracket and pull it out.
11. Unscrew the torque support on the body and swivel upwards.
12. Release the secondary air pump from the cylinder bank 1 - 4. To do this unscrew the 3 fastening screws, remove the pump from the holder and place it on one side.
13. Unscrew the 4 fastening screws on the design cover.
14. Remove design cover from the cylinder bank 1 - 4. Lift the cover slightly with both hands on the side pointing towards the intake system until it snaps out of the mounting bosses.
15. Lift the cover on the front edge and slide the ignition coil cover of the second cylinder out of the torque support bracket. Then pull off the cover to the front.
16. Remove engine compartment cover on the right side. To do this unscrew the 4 bayonet screws and the fastening screw on the windshield washer reservoir.
17. Unscrew the torque support. To do this unscrew the fastening screw on the torque support bracket and pull it out.
18. Unscrew the torque support on the body and swivel upwards.
19. Release the secondary air pump from the cylinder bank 1 - 4. To do this unscrew the 3 fastening screws, remove the pump from the holder and place it on one side.
20. Unscrew the 4 fastening screws on the design cover.
21. Remove design cover from the cylinder bank 1 - 4. Lift the cover slightly with both hands on the side pointing towards the intake system until it snaps out of the mounting bosses.
22. Lift the cover on the front edge and slide the ignition coil cover of the second cylinder out of the torque support bracket. Then pull off the cover to the front.
23. Unscrew the 4 fastening screws on the design cover 5 - 8.
24. Remove design cover of cylinder bank 5 - 8. To do this lift the cover slightly with both hands on the side pointing towards the intake system until it is released from its retainer.
25. Lift the front of the designer cover and remove it.
26. Disconnect positive crankcase ventilation on the two valve covers. To do this press the plastic ring and pull the connections. Then remove the positive crankcase ventilation from the retaining clip.
Positive crankcase ventilation connection
27. Then disassemble the line between the oil mist collector and the intake distributor.
28. Separate fuel line on the plenum panel.
29. Disconnect the 8 injection valves. To do this, press the metal clip on the plug and pull off the plug.
30. Unscrew the fastening screws on the intake distributor-in the sequence shown-.
31. Remove intake distributor from the engine in an upward direction.
Installing intake distributor
1. Replace intake distributor gaskets.
2. Place intake distributor on the engine and tighten the screws in 2 stages in the sequence shown below.
Stages Tightening torque [Nm] (ftlb.)
I 10 (7.5)
II 15 (11.0)
3. Connect the 8 electric connectors to the injection valves. The connectors must engage audibly.
4. Install positive crankcase ventilation. The 2 connections must audibly engage. Then close the mounting clip.
5. Install line between intake distributor and oil mist collector.
6. Connect vacuum line to the rear of the intake distributor. The plug must engage audibly.
7. Attach the vacuum line to the underside of the Y pipe.
8. Slide the bellows onto the air flow sensors and tighten the hose clamps.
9. Slide the Y pipe onto the throttle positioner. Then insert the left and right retainer bolts. Turn the right bolt 45 degrees clockwise and the left bolt 45 degrees anti-clockwise.
10. Connect the throttle positioner. The connector must engage audibly. Clip the connecting cable into the sheet metal support.
11. Press the 4 rubber elements in the cover onto the 4 ball socket holders. The fastening elements must lock in firmly.
12. Slide the design cover of the cylinder bank 1 - 4 under the secondary air pump as shown in the picture and then slide the cover of the second ignition module through underneath the torque support bracket.
13. Press down the 2 rubber mounts on the support. The rubber mounts must engage firmly.
14. Tighten the 4 fastening screws on the ignition coils to 4 - 5 Nm (3.0 - 3.5 ftlb.).
15. Reinstall secondary air pump. Tighten the 3 fastening screws to 10 Nm (7.5 ftlb.).
16. Reinstall torque support. Install the fastening screw (M10 x 70) with a new fastening nut on the bracket. Tightening torque 60 Nm (44 ftlb.).
17. Tighten torque support fastening screw on the body (M10 x 20) to 60 Nm (44 ftlb.).
18. Install engine compartment cover on the right side. To do this tighten the 4 bayonet screws and the sheet metal screw on the windshield washer reservoir.
19. Slide design cover under the secondary air pump as shown in the picture.
20. Then press down the 2 rubber mounts on the support. The rubber mounts must engage firmly.
21. Tighten the 4 fastening screws on the ignition coil to 5 Nm (3.5 ftlb.).
Tightening torques
