Overhaul

WM 244619 Removing and installing intake-air distributor

Preliminary work

Preliminary work for turbo engines

1. Remove engine cover (design cover). -> 108319 Removing and installing engine cover (design cover) - section on "Removing" 108319 Removing and installing engine cover (design cover).
2. Remove oil mist separator. -> 105519 Removing and installing oil mist separator Service and Repair
3. Loosen intake port on throttle housing. For details, see -> 243519 Removing and installing air box for throttle housing 243519 Removing and installing cowl for throttle housing (Y-pipe)
4. Disconnect ventilation lines at the intake-air distributor => Ventilation on turbo engines.





Ventilation on turbo engines





Removing intake-air distributor

Removing intake-air distributor on turbo engines





Intake air module on turbo engine





1. Loosen connections on the intake-air distributor.





Intake-air distributor connections at the front

1.1. Release and pull off electric plug connection on the heat socket -1-.
1.2. Disconnect hose connection -2- for positive crankcase ventilation on heat socket.
1.3. Release and unplug electric plug connection on the throttle housing -3- , then loosen the sheetmetal clip.
1.4. Disconnect cable connection for tank vent line on the intake-air distributor. ???
2. Release and unplug electric plug connection on the pressure sensor -4-.
3. Loosen screws on the intake-air distributor. Illustration shows tightening sequence => Tightening sequence for intake-air distributor (shown on naturally aspirated engine).





Tightening sequence for intake-air distributor (shown on naturally aspirated engine)

4. Pull off vacuum line. -Vacuum Line-





Vacuum line

5. Lift off intake-air distributor.
6. Cover intake ducts on the cylinder head to prevent dirt from getting in (using strips of adhesive tape for example).

Installing intake-air distributor

Installing intake-air distributor on turbo engines

Information

- The tightening specifications for the basic engine are stored centrally. -> 1001IN Tightening torques, tightening sequences, assembly overviews [1][2]Specifications. Tightening torques and assembly instructions for other assemblies (e.g. chassis, electrics, transmission or body) or for peripheral engine equipment can be found in the corresponding documents.

Information

If screws are damaged, take the intake-air distributor off again and carefully tap out the affected screws with a plastic hammer. Carefully tap in new screw elements with a plastic hammer.

1. The intake-air distributor is installed in reverse order to removal.
2. Instructions for fitting the intake-air distributor:
- Replace intake-air distributor gaskets.
- Move intake-air distributor into installation position. Make sure that the gaskets do not slip out of place and that the lines are not trapped.
- Pull off vacuum line.
- Carefully screw in screws on intake-air distributor. Screws must all fit easily. Align intake-air distributor with screws tightened slightly and then tighten screws according to the tightening sequence.





Vacuum line





Tightening sequence for intake-air distributor (shown on naturally aspirated engine)

Subsequent work

Subsequent work turbo engines

1. Secure ventilation lines at the intake-air distributor => Ventilation on turbo engines.





Ventilation on turbo engines





2. Install oil mist separator. -> 105519 Removing and installing oil mist separator Service and Repair
3. Secure intake port on throttle housing. -> 243519 Removing and installing air box for throttle housing (Y-shaped pipe) - section on "Installing" 243519 Removing and installing cowl for throttle housing (Y-pipe)
4. Install engine cover (design cover). -> 108319 Removing and installing engine cover (design cover) - section on "Installing" 108319 Removing and installing engine cover (design cover).