Intake Air Plenum: Testing and Inspection

Checking The Intake Distributor For Leaks







Required tools

Item A - C:

Leak test

NOTE:
- The specified description can be used to check the intake system from the air cleaner outlet to the injection valves for leaks.
- Cylinders must not be located in the overlapping TDC. This happens only if the crankshaft was turned manually.

1. Remove engine compartment cover.
2. Disconnect connections on the air cleaner covers. To do this, turn the pins through 180 degrees and pull them out. Then pull off the intake manifolds.







3. Connect plugs 9264/7 to the two air cleaner connections and push in the safety bracket. Then connect a compressed-air hose to the connection on the plug.







WARNING:
Risk of damage
- Do not subject intake system to excessive air pressure (max. 1.2 bar).

CAUTION:
Danger of injury.
- Do not pull out the oil dipstick or open the engine during the test procedure.

4. Set compressed-air reducer to 0.2 bar (approx. 1.2 bar absolute pressure).
5. Push a compressed-air hose onto the connection from plug 9264/7 and connect the other end to the compressed-air reducer.
6. Spray the intake system systematically with a leak-locating spray. Bubbles can be seen clearly at the locations where there are leaks.

View shows a leaking Y pipe -arrow-







NOTE:
- Any leaks that exist between the air cleaner cover and the intake distributor seal can be located using this method.
- Proceed systematically with the check.

7. Seal defective areas.
8. Remove special tool.
9. Push the connections onto the cover of the air cleaner housing and mount and lock the fastening pins.







10. Fit engine compartment cover.