Removing and Installing Intake Distributor
Removing and Installing Intake-air Distributor
Tools
Technical values
Preliminary work
Preliminary work for removing intake distributor
1. Disconnect the battery.
2. Remove air cleaner housing.
3. Remove tuning pipe.
General warning notes
Danger from Pentosin
WARNING:
Danger of injury and material damage when using Pentosin.
- Risk of skin irritation and damage to skin.
- Damage to hoses and wiring.
- Wear protective gloves and goggles.
- In the event of contact (eyes or skin), wash immediately with water.
- Collect emerging Pentosin.
- Use caps to protect the wiring against soiling and damage.
- Clean hoses and wiring immediately.
Removing intake distributor, cylinder bank 1-3
WARNING:
Danger of injury and material damage when using Pentosin.
- Risk of skin irritation and damage to skin.
- Damage to hoses and wiring.
- Wear protective gloves and goggles.
- In the event of contact (eyes or skin), wash immediately with water.
- Collect emerging Pentosin.
- Use caps to protect the wiring against soiling and damage.
- Clean hoses and wiring immediately.
INFORMATION: For better accessibility when removing the intake distributor from cylinder bank 1-3, the three-phase generator should be removed.
1. Remove three-phase generator.
2. Open line connections in left of engine compartment.
2.1. Loosen the vacuum lines for the brake booster -1-. For the tandem pump feed line, remove the plastic protection, push the holder forward and pull off the line. Immediately put plastic protection back in place.
2.2. Disconnect tank vent line -2-. In order to do this, press the lugs of the rapid-action coupling and pull off the line (vent line remains fitted -3- ).
3. Remove plastic lines from cable holder over the fuel distributor pipe -1- and pull cable holder up and off.
4. Release lines over the fuel distributor pipe (unclip lines from the holders and secure with a tie-wrap to the coolant expansion tank).
5. Unclip the two coolant hoses -1- and aluminium pipe of the brake booster -2- from the holders on the transverse member and carefully lay to one side.
6. Remove cable plug from switch-over valve -3-. Pull vacuum pipes off the switch-over valve -4-.
7. Remove cable duct on the fuel distributor pipe. To do this, pull cable plug from camshaft position sensor -2- and lift up cable duct.
8. Remove fastening screws for fuel distributor pipe -1- and pull fuel distributor pipe together with fitted injection valves from the intake distributor. Check sealing rings of injection valves and replace if necessary.
CAUTION:
Material damage through lowering engine
- Cables and coolant hoses can be stretched and torn
- Lower the engine with a jack no more than 40 mm maximum
9. Support the engine with a jack. Unscrew the two collar nuts of the rear engine mounts. Lower the engine by 30 - 40 mm. Should the period between removal and installation be extended, the engine must be lifted back into position and temporarily secured with the collar nuts. Attach an appropriate warning notice.
10. Remove the four fastening screws of the intake distributor (illustration shows cylinder bank 4-6) -arrows-. If necessary, use a mirror to remove the front-most screw. When removing the intake distributor, leave the fore-most screw in its bore in the intake distributor. Carefully remove the intake distributor from the engine compartment (carefully release vacuum lines to the switch-over valve). Replace seals.
INFORMATION: Cover engine openings (e.g. intake openings, crankcase, oil lines, open reservoirs etc.) cover with a cloth to avoid dirt and foreign bodies falling in.
11. Cover engine openings with a cloth.
Installing intake distributor, cylinder bank 1-3
1. Clean the sealing surfaces of the intake distributor and crankcase.
2. Replace the seals in the intake distributor and insert correctly into the grooves of the intake distributor.
3. Place intake distributor in installation position. At the same time, pull through and lay the vacuum lines to the switch-over valve -4-.
INFORMATION: If necessary, to ease installation of the intake distributor, insert the rear fastening screw in its bore in the intake distributor before commencing installation.
The socket for tightening the fastening screws of the intake distributor should be secured with a strip of insulating tape to prevent them falling out.
If necessary, carry out the work using a small mirror.
4. Screw in and tighten fastening screws of the intake distributor, using a magnet if necessary - Tightening torque: 7.5 ftlb.
5. Check sealing rings of injection valves and replace if necessary. Clean sealing surfaces with a lint-free cloth and apply a thin coat of silicone spray. Insert fuel distributor pipe together with fitted injection valves into the appropriate openings of the intake distributor and screw in the fastening screws of the fuel distributor pipe to the intake distributor -1-. Tighten screws - Tightening torque: 7.5 ftlb.
6. Lift engine into position with the car jack and fasten - Tightening torque: 63 ftlb.
7. Move cable duct into position on the fuel distributor pipe and clip in. Connect cable plugs for switch-over valve -1- and camshaft position sensor -2-.
8. Fit cable plug to switch-over valve -1-. Fit vacuum pipes to the switch-over valve -4-.
9. Separate the tie-wraps and move lines into the installation position.
10. Fit cable holders by pushing onto intake distributor and fuel distributor tube. Clip plastic lines into cable holders and connect and secure the remaining lines.
11. Clip the two coolant hoses and aluminium pipe of the brake booster into the holders on the transverse member.
12. Fit line connections in left of engine compartment.
12.1. Fit vacuum lines for the brake booster -1-. Fit the tandem pump feed line into the holder (plastic protection must be fitted beforehand).
12.2. Connect tank vent line -2-, pressing the rapid-action coupling onto the line.
13. Install three-phase generator.
Removing intake distributor, cylinder bank 4-6
CAUTION:
Material damage through lowering engine
- Cables and coolant hoses can be stretched and torn
- Lower the engine with a jack no more than 40 mm maximum
INFORMATION:
- Cover engine openings (e.g. intake openings, crankcase, oil lines, open reservoirs etc.) cover with a cloth to avoid dirt and foreign bodies falling in.
- After removal, place the air-conditioning compressor on a suitable protective support (e.g. foam, neoprene, etc.).
WARNING:
Danger of injury and material damage when using Pentosin.
- Risk of skin irritation and damage to skin.
- Damage to hoses and wiring.
- Wear protective gloves and goggles.
- In the event of contact (eyes or skin), wash immediately with water.
- Collect emerging Pentosin.
- Use caps to protect the wiring against soiling and damage.
- Clean hoses and wiring immediately.
1. Remove fastening screw of servo-tank from intake distributor -arrow-. 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 - Servo-tank bayonet lock. Immediately seal the lower tank opening with a suitable plug.
INFORMATION: The air-conditioning lines on the compressor do not have to be disconnected in order to remove engine/transmission unit.
2. Detach air-conditioning compressor without disconnecting the air-conditioning lines.
3. Disconnect ground connector from intake distributor side 4-6 -arrow-.
4. Pull the engine compartment temperature sensor out of the intake distributor 4-6 together with the rubber sleeve -1- and unscrew the rear fastening screws -2- of the air-conditioning compressor.
5. Unscrew the front fastening screw -arrow- of the air-conditioning compressor. Due to the restricted accessibility, the use of a 3/8 inches extension, 16 degrees movable NR.15 with a long Torx E10 socket wrench is recommended. To lift out the air-conditioning compressor, the screw must be pulled upwards and held in position.
6. Lift out the air-conditioning compressor with the leads connected and lay to one side on a protective support. Secure additionally with a tie-wrap.
7. Pull the sheetmetal holder between the servo oil lines out of the rubber mounts and remove -arrow-.
8. Remove plastic line between oil mist separator and oil flange and lay to one side.
9. Unscrew the two fastening screws of the oil flange behind the servo oil lines and remove the oil flange -arrows-. Replace seal.
10. Remove fastening screws for fuel distributor pipe -1- and pull fuel distributor pipe together with fitted injection valves from the intake distributor. Check sealing rings of injection valves and replace if necessary.
CAUTION:
Material damage through lowering engine
- Cables and coolant hoses can be stretched and torn
- Lower the engine with a jack no more than 40 mm maximum
11. Support the engine with a jack. Unscrew the two collar nuts of the rear engine mounts. Lower the engine by 30 - 40 mm. Should the period between removal and installation be extended, the engine must be lifted back into position and temporarily secured with the collar nuts. Attach an appropriate warning notice.
12. Remove the four fastening screws of the intake distributor -arrows-. If necessary, use a mirror to remove the front-most screw. When removing the intake distributor, leave the fore-most screw in its bore in the intake distributor. Carefully remove the intake distributor from the engine compartment (carefully release vacuum lines to the switch-over valve). Replace seals.
INFORMATION: Cover engine openings (e.g. intake openings, crankcase, oil lines, open reservoirs etc.) cover with a cloth to avoid dirt and foreign bodies falling in.
13. Cover engine openings with a cloth.
Installing intake distributor, cylinder bank 4-6
1. Clean the sealing surfaces of the intake distributor and crankcase.
2. Replace the seals in the intake distributor and insert correctly into the grooves of the intake distributor.
3. Place intake distributor in installation position. At the same time, pull through and lay the vacuum lines to the switch-over valve.
INFORMATION: If necessary, to ease installation of the intake distributor, insert the rear fastening screw in its bore in the intake distributor before commencing installation.
The socket for tightening the fastening screws of the intake distributor should be secured with a strip of insulating tape to prevent them falling out.
If necessary, carry out the work using a small mirror.
4. Screw in and tighten fastening screws of the intake distributor, using a magnet if necessary - Tightening torque: 7.5 ftlb.
5. Lift engine into position with the car jack and fasten - Tightening torque: 63 ftlb.
6. Check sealing rings of injection valves and replace if necessary. Clean sealing surfaces with a lint-free cloth and apply a thin coat of silicone spray. Insert fuel distributor pipe together with fitted injection valves into the appropriate openings of the intake distributor and screw in the fastening screws of the fuel distributor pipe to the intake distributor -1-. Tighten screws - Tightening torque: 7.5 ftlb.
7. Move cable duct into position on the fuel distributor pipe and clip in.
8. Replace oil flange seal. Place oil flange in installation position. Screw in the two fastening screws of the oil flange -arrows- and tighten - Tightening torque: 7.5 ftlb.
9. Fit plastic line between oil mist separator and oil flange.
10. Fit sheetmetal holder between servo lines into rubber mounts -arrow-.
11. Fit air-conditioning compressor: before installing the compressor check whether the aluminium spacer sleeve -arrow- is inserted. Grease and fit sleeve. Also lay the ground cable before installation.
12. Fit air-conditioning compressor and fasten using three M8 Torx screws (two short ones at the rear, one long one at the front) -1-. See details and tightening torques.
13. Connect ground connector to intake distributor side 4-6 -arrow-.
14. Fit drive belt. Pay attention to operating direction of used belts. Double-check that the position of the belt on the belt pulleys is correct.
WARNING:
Danger of injury and material damage when using Pentosin.
- Risk of skin irritation and damage to skin.
- Damage to hoses and wiring.
- Wear protective gloves and goggles.
- In the event of contact (eyes or skin), wash immediately with water.
- Collect emerging Pentosin.
- Use caps to protect the wiring against soiling and damage.
- Clean hoses and wiring immediately.
15. Check sealing rings on servo-tank and replace if necessary. Fit servo-tank by carefully inserting the tank into the opening of the servo pump and fastening the bayonet lock in the clockwise direction. Fit fastening screw of servo-tank to intake distributor - Tightening torque: 7.5 ftlb. Fill servo-tank with Pentosin fluid and check oil level.
Subsequent work
Subsequent work for installing intake distributor
1. Install tuning pipe.
2. Install air cleaner housing.
3. Connect the battery.