Intake Manifold: Service and Repair

Removing And Installing Intake-air Distributor

Tools







Technical values







Information

Overview







Preliminary work

1. Disconnect battery.
2. Remove pressure pipe.
3. Remove air cleaner housing.

DANGER:
Risk of engine falling down.
- Danger of fatal injury, material damage.

- Support the engine with the prescribed tool.

4. Lower the engine.
Lower the engine by max. 40 mm.
Support the engine with a jack and retainer plate P 9592.

4.1. Loosen collar nuts on engine mounting and unscrew. Carefully lower engine using the jack.

General warning notes

Danger from fuel

DANGER:
Fuel can escape when fuel line is disconnected.
- Risk of fatal injury.
- Damage to skin.

- Do not work on fuel system if engine is hot.
- Do not smoke, avoid fire and naked flames.
- Wear fuel-resistant protective gloves and goggles.
- Attach warning sign to vehicle in a clearly visible position.

Hot engine components

WARNING:
Risk of injury from hot engine and hot engine fluids.
- Danger of burns, scalding, damage to skin, injury to the eyes.

- Do not carry out work on the engine while it is hot.

Removing intake-air distributor

Removing centre intake-air distributor







1. Remove the transverse strut.
Unscrew M6 screws and remove transverse strut -1-.







2. Disconnect line connections from the intake-air distributor -2, 3, 4, 5-.
3. Remove centre intake-air distributor.







3.1. Remove holder -6-.
3.2. Pull off cable plugs -8-.
3.3. Loosen hose band clamps -7- and move rubber sleeves outwards. Remove centre intake-air distributor -9-.

Removing intake-air distributor, side 1-3







1. Attach or mount fire hazard warning sign in a clearly visible position.







2. Remove fuel filter.
3. Open line connections in left of engine compartment.







3.1. Disconnect and remove carbon canister line -2-.
3.2. Remove coolant ventilation -1- at the tank.
3.3. Disconnect vacuum line -3-.







3.4. Expose lines above the fuel distribution pipe.
Unclip the lines from the holders and secure them on the coolant expansion tank using a tie-wrap.







4. Remove secondary-air pump.
5. Loosen intake air line at the turbocharger 1-3.
Intake air line cannot be removed.







5.1. Unscrew two M6 screws -arrows- and one M6 collar nut -1-. Disconnect intake air line with retaining bracket.







5.2. Press intake air line out of the bracket in the engine compartment.
5.3. Replace O-ring during assembly and grease with Kluber Syntheso Glep (Part No. 000.043.204.68).







6. Remove oil-filter console.

CAUTION:
Low load capacity of pipe and line connections.
- Damage and leaks at pipe and line connections.

- Always counter at the lines when loosening and fastening them.

7. Detach wiring harness and fuel line from the fuel collection pipe.
7.1. Pull cable rail -3- upwards at the fuel collection pipe and press to the side.
7.2. Disconnect cable plug -arrows- at the fuel injectors 1-3.







7.3. Detach fuel line -2- (a/f 17 and 19) and unscrew.







8. Remove intake-air distributor.
Unscrew screws -3- and carefully remove intake-air distributor -1- with left fuel collection pipe.
Use a 6-mm screwdriver insert with ball joint for screws that are difficult to reach.


Removing intake-air distributor, side 4-6

1. Remove rear apron.
2. Remove charge air cooler on right.







3. Remove oil filler neck with holder.
3.1. Remove oil filler neck -5-.
3.2. Remove holder -7- for oil filler neck.

4. Detach air conditioning compressor.







4.1. Disconnect fuel line.







4.2. Pull engine compartment temperature sensor -1- out of the rubber holder.







4.3. Unscrew the fuel lines from the fuel cooler.
Counter at the fuel cooler (a/f 14) when unscrewing the union nuts -4-.

CAUTION:
Low load capacity of pipe and line connections.
- Damage and leaks at pipe and line connections.

- Always counter at the lines when loosening and fastening them.

4.4. Remove compressor.
Remove three M8 screws -5-. Carefully remove compressor, place to one side together with refrigerant lines (use protective surface). If necessary, secure with a tie-wrap to prevent them from slipping.

5. Remove the engine wire harness to create better access to the fuel collection pipe.







5.1. Cut tie-wrap -arrow-.







5.2. Open round connectors on engine wire harness.
To do this, turn bayonet lock anticlockwise and pull off.







5.3. Unplug cable plug for cylinder 4 ignition coil -1-.
Pull cable plug -2- off the camshaft sensor.

5.4. Pull cable rail upwards from fuel collection pipe -arrow-.

CAUTION:
Low load capacity of pipe and line connections.
- Damage and leaks at pipe and line connections.

- Always counter at the lines when loosening and fastening them.

6. Detach oil line from the oil tank.







6.1. Loosen oil line -1- from the oil tank -2- using crow foot wrench, a/f 32 Nr.189. Counter with an open-ended wrench (a/f 32) while doing this. Unscrew union nut.
6.2. Press line to one side to remove the fuel collection pipe.







7. Remove fuel collection pipe with fuel injectors 4-6.
7.1. Detach fuel line (a/f 17 and 19).
7.2. Remove two M6 screws -13-.
7.3. Detach fuel collection pipe -2- with fuel injectors 4-6 from the intake-air distributor.
7.4. Disconnect cable plug for fuel injectors 4-6.
7.5. Guide out fuel collection pipe -2- in the direction of travel until it is exposed and can be removed.







8. Remove right intake-air distributor.
Lift right intake-air distributor -1- and twist slightly until it is free, then remove it over the hydraulic pump.
Use a 6-mm screwdriver insert with ball joint for screws that are difficult to reach.

Installing intake-air distributor

Installing intake-air distributor, side 1-3

1. Install intake-air distributor with fuel collection pipe.







1.1. Clean sealing surfaces on the intake-air distributor and cylinder head.
1.2. Replace the seals in the intake-air distributor and insert into the grooves of the intake-air distributor.







1.3. Check the seals -11 and 12- of the fuel injectors -9- and replace them if necessary.
Clean sealing faces with a lint-free cloth and apply a thin coat of silicone spray.

1.4. Fit fuel injectors into fuel collection pipe and secure them using spring clamps.
1.5. Insert fuel collection pipe with fuel injectors fitted into the corresponding openings in the intake-air distributor.
1.6. Fit and tighten M6 fastening screws for the fuel collection pipe -1-.
- Tightening torque: 10 Nm (7.5 ftlb.)







1.7. Carefully insert left intake-air distributor -1- , fit and tighten screws -3-.
Use 6 mm screwdriver insert with ball joint for screws that are difficult to reach.
- Tightening torque: 10 Nm (7.5 ftlb.)

CAUTION:
Low load capacity of pipe and line connections.
- Damage and leaks at pipe and line connections.

- Always counter at the lines when loosening and fastening them.

2. Fit fuel line and wiring harness.







2.1. Connect fuel line. Fit and tighten union nut -2- (a/f 17 and 19).
- Tightening torque: 30 Nm (22 ftlb.)

2.2. Connect cable plug -arrows- for fuel injectors 1-3.
2.3. Clip on cable rail -3- at the fuel collection pipe.

3. Fit intake air line for side 1-3.







3.1. Position intake air line in the bracket -arrow- in the engine compartment.







3.2. Fit intake air line together with new O-ring and retaining bracket at the turbocharger flange and press it in. Fit and tighten two screws -arrows- and one M6 collar nut -1-.
- Tightening torque: 10 Nm (7.5 ftlb.)







4. Install secondary-air pump.
- Tightening torque: 10 Nm (7.5 ftlb.)







5. Install oil-filter console.
- Tightening torque: 23 Nm (17 ftlb.)
- Tightening torque: 10 Nm (7.5 ftlb.)

6. Fit lines on left of engine compartment.







6.1. Open tie-wrap and move lines into installation position.







6.2. Insert carbon canister line -2- and connect.
6.3. Connect coolant breather hose -1- to coolant expansion tank.
6.4. Connect the vacuum line -3-.







7. Install fuel filter.

Installing right intake-air distributor

1. Install intake-air distributor.







1.1. Clean sealing surfaces on the intake-air distributor and crankcase.
1.2. Replace the seals in the intake-air distributor and insert into the grooves







1.3. Introduce right intake-air distributor, twist slightly and insert, fit and tighten screws.
Use 6 mm screwdriver insert with ball joint for screws that are difficult to reach.
- Tightening torque: 10 Nm (7.5 ftlb.)

CAUTION:
Low load capacity of pipe and line connections.
- Damage and leaks at pipe and line connections.

- Always counter at the lines when loosening and fastening them.







2. Install fuel collection pipe with fuel injectors 4-6.
2.1. Replace O-rings of the fuel injectors.
2.2. Clean sealing faces with a clean, lint-free cloth. Apply a thin coat of silicone spray to the O-rings.
2.3. Insert fuel injectors onto fuel collection pipe -2- and secure them using spring clamp.
2.4. Press fuel collection pipe -2- with fuel injectors 4-6 into the mountings in the intake-air distributor.
2.5. Fit and tighten M6 screws -13-.
- Tightening torque: 10 Nm (7.5 ftlb.)

3. Fit fuel lines.
3.1. Screw fuel line (a/f 17 and 19) onto fuel collection pipe and tighten it.
- Tightening torque: 30 Nm (22 ftlb.)

3.2. Screw fuel line onto pressure regulator and tighten it.
- Tightening torque: 30 Nm (22 ftlb.)

4. Attach cable rail and connect engine wire harness.
4.1. Connect cable plug to the fuel injectors 4-6.
4.2. Connect cable plug for cylinder 4 ignition coil -1-.






4.3. Connect cable plug -2- for hall sender.
4.4. Clip on cable rail at the fuel collection pipe -arrow-.







4.5. Connect engine wiring harness.







Fit round connector onto connector bracket and turn clockwise until it reaches the locking point.

4.6. Secure engine wire harness with tie-wraps.

5. Fit oil line at the oil tank.







5.1. Fit union nut and secure oil line -1- to the oil tank -2- using crow foot wrench, a/f 32 Nr.189. Counter with an open-ended wrench (a/f 32) while doing this.
- Tightening torque: 60 Nm (44 ftlb.)

6. Fit air conditioning compressor.
6.1. Insert compressor carefully. Fit and tighten M8 screws -5-.
- Tightening torque: 23 Nm (17 ftlb.)







6.2. Screw on and tighten the fuel lines at the fuel cooler.
Counter at the fuel cooler (a/f 14) when tightening the union nuts -4-.
- Tightening torque: 25 Nm (19 ftlb.)







6.3. Insert engine compartment temperature sensor into the rubber holder.







6.4. Secure fuel line.







7. Install oil filler neck with holder.
7.1. Install holder for oil filler neck.
- Tightening torque: 10 Nm (7.5 ftlb.)

7.2. Install oil filler neck.

8. Install right charge air cooler.
9. Install rear apron.

Installing centre intake-air distributor

1. Install centre intake-air distributor.







1.1. Insert centre intake-air distributor. Push rubber sleeves inwards and then position them. Tighten hose band clamps -7-.
1.2. Push on cable plug -8-.
1.3. Install holder -6-.







2. Connect line connections to the centre intake-air distributor.
Connect line connections -2, 3, 4, 5- to the centre intake-air distributor.







3. Install the transverse strut.
Position transverse strut -1- , screw in and tighten screws.
- Tightening torque: 10 Nm (7.5 ftlb.)

Subsequent work

1. Raise the engine.
Raise the engine to assembly position using a retainer plate P 9592.
Screw in and tighten collar nuts for engine mounting.
- Tightening torque: 85 Nm (63 ftlb.)

2. Install air cleaner housing.
3. Install pressure pipe.
4. Connect the battery.