Removal and Replacement
WM 244619 Removing and installing intake-air distributor - X51.
Tools
Technical values
Preliminary work
Information
Specifications for wrench sizes (a/f specifications) for screw heads are described as follows:
- Torx screws: (E.) for external Torx, (T.) for internal Torx.
- Hexagon-head bolts (internal and external hexagon): Wrench size (a/f)
1. Disconnect ground strap on the battery.
2. Remove air cleaner housing.
=> 242519 Removing and installing air cleaner housing.
WARNING
Objects or loads falling down
- Risk of squashing or crushing
-> Secure components to prevent them from falling down.
Information
- It may only be supported over a large area at the oil pan.
- Localised loading is not permitted.
3. Support the engine at the oil pan using hydraulic garage jack H 2 SL WE 1032 and transmission jack plate of transmission jack V.A.G. 1383 A WE 1082.
3.1. Loosen two special M12 nuts (internal Torx, screw insert T55) -1- on the engine mounting (hydraulic mount) at the left and right until the engine can be lowered by about 30 mm.
Engine carrier to engine mounting on cylinder bank 4-6 (view from below)
Information
- When lowering, the engine must not rest on the rear axle cross member.
4. Slowly lower the engine by about 30 mm (measured at the engine carrier) using the jack.
4.1. Place a flat piece of wood on rear axle carrier if necessary.
5. Disconnect connectors and loosen M6 hexagon nut on throttle housing.
5.1. Remove M6 hexagon nut -1- from throttle housing support.
5.2. Disconnect electronic throttle cable plug -3- and unclip -Arrow- , Detach rapid action couplings at tank vent -2- and crankcase ventilation -4-.
Connections at throttle housing
5.3. Detach positive crankcase ventilation line -1- and cable -2- for throttle connector and unclip -Arrows-.
Positive crankcase ventilation line and cable for throttle connector.
6. Remove oil filler neck support -1- and tank vent.
6.1. Release and disconnect cable plug -3- , Detach tank vent at clip -Arrow-.
6.2. Detach rapid-action coupling of tank vent line and set line aside.
6.3. Unscrew four M6 x 12 outer Torx screws (E10) -2- and remove support.
Remove oil filler neck support and tank vent.
7. Remove top part of oil filler neck (plastic) -3-.
7.1. Disconnect crankcase vent line -2-.
7.2. Unscrew four M6 x 16 external Torx screws (E10, micro-encapsulated) -4- , remove oil filler neck.
7.3. Replace sealing ring and screws.
Oil filler neck
8. Remove the throttle housing.
=> 244219 Removing and installing throttle housing.
8.1. Replace sealing ring.
Removing intake-air distributor
1. Detach intake-air distributor.
1.1. Unscrew eight M6 x 30 external Torx screws (E10, micro-encapsulated) in each case -1-.
1.2. Remove screws using a bar magnet..
1.3. Replace micro-encapsulated screws.
Overview of screws, intake-air distributor
2. Unscrew plastic clip at intake-air distributor 4-6 (positive crank case ventilation fastening).
3. Unclip electric control valve -1- from (rear) central intake-air distributor.
Control valve at central intake-air distributor
4. Remove oil filler pipe (aluminium) -1- , lift the intake-air distributor slightly for this purpose.
4.1. Remove positive crankcase ventilation line -2- , remove two M6 x 20 external Torx screws (E10) -3-.
Oil filler pipe
4.2. Pay attention to the sleeves -1- on the oil filler pipe flange. Remove these before removing the oil filler pipe.
Oil filler pipe sleeves
5. Remove intake-air distributor assembly -1- from the engine compartment over the generator -Arrow-.
Lifting the intake-air distributor out of the engine compartment
6. Replace seals on intake pipes.
7. The intake-air distributor can be cleaned in a parts washing machine without aggressive cleaning agents.
8. Carefully clean and cover sealing faces on intake pipes.
Installing intake-air distributor
Information
Always replace gaskets and O-rings.
- Grease all gaskets (except for the cooling system) with Kluber Syntheso Glep (Part No. 000.043.204.68).
1. Fit new seals on intake pipes.
1.1. Apply a thin bead of Doboseal sealant (length approx 30 mm) in the area of the selector shaft oil seal -Arrows-.
Intake manifold removed
1.2. Grease seals lightly with Kluber Syntheso Glep (Part No. (Porsche part number 000.043.204.68) (not in the sealant area!).
2. Guide the intake-air distributor into the engine compartment and carefully fit onto the intake pipes.
2.1. Position eight external Torx screws (E10, M6 x 30) in each case. Use a bar magnet if required.
2.2. Clip in control valve -1-.
Control valve at central intake-air distributor
3. Install oil filler pipe (aluminium) -1- with a new O-ring.
3.1. Grease O-ring using the prescribed lubricant.
3.2. Position oil filler pipe in crankcase flange.
3.3. Insert two sleeves and insert two external Torx screws (E10, M6 x 20) -3-.
3.4. Connect crankcase ventilation line -2-.
Oil filler pipe
4. Fasten intake-air distributor.
4.1. Insert and tighten eight new external M6 x 30 Torx screws (E10, microencapsulated) -1- from the inside out.
=> Tightening torque: 13 Nm (7.4 ftlb)
Overview of screws, intake-air distributor
5. Install oil filler neck upper part (plastic) -3- with a new O-ring.
5.1. Grease O-ring using the prescribed lubricant.
5.2. Insert and tighten four M6 x 16 external Torx screws (E10) -4-.
=> Tightening torque: 13 Nm (7.4 ftlb)
5.3. Connect crankcase ventilation line -2-.
Oil filler neck
Subsequent work
1. Attach oil filler tube support -1- with M6 x 12 external Torx screws (E10) -2-.
1.1. Tighten the screws.
=> Tightening torque: 10 Nm (7.4 ftlb)
1.2. Attach tank vent with rubber grommet to support -Arrow-.
1.3. Connect cable plug -3- and connect vent line to the upper rapid-action coupling.
Oil filler pipe and tank vent support
2. Fit and tighten two M6 x 20 external Torx screws (E10) at the oil filler pipe flange.
=> Tightening torque: 13 Nm (9.5 ftlb)
3. Install throttle housing with new sealing ring.
=> 244219 Removing and installing throttle housing.
4. Attach connectors and fasten M6 hexagon nut on throttle housing.
4.1. Fit and tighten M6 hexagon nut -1- on the throttle housing support.
=> Tightening torque: 6 Nm (4.4 ftlb)
4.2. Connect electronic throttle cable plug -3- and clip in -Arrow- , Attach rapid action couplings at tank vent -2- and crankcase ventilation -4-.
Connections at throttle housing
4.3. Clip in cable -2- for throttle connector and positive crankcase ventilation line -1- -Arrows-.
Positive crankcase ventilation line and cable for throttle adjuster connector.
WARNING
Objects or loads falling down
- Risk of squashing or crushing
-> Secure components to prevent them from falling down.
5. Slowly raise engine to its installation position using the jack.
6. Tighten two M12 special nuts (inner Torx, screw insert T55) -1- at the engine mounting (hydraulic mount) on the left and right.
=> Tightening torque: 85 Nm (63 ftlb)
6.1. Remove piece of wood from rear axle carrier if necessary.
Engine carrier to engine mounting on cylinder bank 4-6 (view from below)
7. Perform intake-air distributor leak test.
=> 244601 Checking intake-air distributor for leaks.
8. Install air cleaner housing.
=> 242519 Removing and installing air cleaner housing.
9. Connect the battery.
=> 2X00IN02 Work instructions after disconnecting the battery.