Intake Air Duct: Service and Repair

WM 243519 Removing and installing air box for throttle housing on DFI engines (intake pipes upstream of throttle valve)

Preliminary work

1. Remove engine compartment cover at the front and on both sides. => 700219 Removing and installing front trim (engine compartment) - section on "Removing"
2. Pull off throttle cover. => 108319 Removing and installing engine cover (design cover) on DFI engines - section on "Removing"

Preliminary work

1. Remove engine compartment cover at the front and on both sides. => 700219 Removing and installing front trim (engine compartment) - section on "Removing"
2. Pull off throttle cover. => 108319 Removing and installing engine cover (design cover) on DFI engines - section on "Removing"

Removing air box for throttle housing (intake pipe upstream of throttle valve)

Information

The Y-pipe on the Turbo S is secured to the throttle housing with a twist lock. => Y-pipe on Turbo S





Y-pipe on Turbo S

1. Disconnect boost pressure sensor. -1-





Y-pipe in front of throttle valve

2. Undo clamps on charge air pipe -2- and undo screws for pressure pipes. -3-
3. Release the fastening bolts on the throttle housing. To do this, feel for the bottom hook by hand and twist the upper hexagon until the bottom hook is free to move. -arrow-





Fastening bolts for throttle housing

4. Press fastening bolts upwards when the hook is free to move and pull out using pointed-nose pliers or by hand. => Fastening bolts





Fastening bolts

5. Pull off Y-pipe (air box) from the throttle housing with a joggling motion. -arrow-





Y-pipe

6. Lever off clip under the Y-pipe with a screwdriver. -arrow- Alternative view -10-





Line bracket under Y-pipe

7. Fold Y-pipe up and push away lines to expose. -11-





Connections under Y-pipe






Installing air box for throttle housing (intake pipe upstream of throttle valve)

Information

The Y-pipe on the Turbo S is secured to the throttle housing with a twist lock. => Y-pipe on Turbo S





Y-pipe on Turbo S

1. Move Y-pipe into installation position in front of throttle valve.
2. Clip in lines on Y-pipe. -11- -10-





Connections under Y-pipe





3. Press Y-pipe (air box) onto the throttle housing with a joggling motion. -arrow- While doing so, press the two rubber bellows at the sides onto the pressure pipes leading to the charge air coolers.





Y-pipe

4. Insert fastening bolts. => Fastening bolts





Fastening bolts

5. Lock the fastening bolts on the throttle housing. -arrow-





Fastening bolts for throttle housing

6. Attach boost pressure sensor. -1-





Y-pipe in front of throttle valve

7. Secure clamps on charge air pipe -2- and fit screws for pressure pipes. -3-

Subsequent work

1. Press on throttle cover.=> 108319 Removing and installing engine cover (design cover) on DFI engines - section on "Installing"
2. Fit engine compartment cover.=> 700219 Removing and installing front trim (engine compartment) - section on "Installing"