Intake Manifold: Service and Repair
Removing And Installing Intake-air Distributor
Tools
Technical values
Preliminary work
1. Disconnect the battery.
2. Remove 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 engine using hydraulic floor jack H 2 SL WE 1032 and transmission jack plate of transmission jack V.A.G 1383 A WE 1082 at the oil pan.
3.1. Loosen two M12 special nuts (inner Torx, screw insert T55) -1- at the engine mounting (hydraulic mount) on the left and right just until the engine can be lowered by around 15 mm.
INFORMATION: When lowering, the engine must not rest on the rear axle cross member.
4. Slowly lower the engine approximately 15 mm using the jack.
5. Remove resonance tube.
6. Loosen threaded connections for cable duct at intake distributor.
6.1. Unscrew M6 x 16 outer Torx screw (E10) -1- at the intake distributor 1 3.
6.2. Unscrew M6 x 16 outer Torx screw (E10) -1- at the intake distributor 4-6.
Information
Component overview for intake-air distributor
Component overview
Overview of screws
Removal
Removing intake-air distributor - side 1-3
1. Release drive belt.
2. Remove generator.
3. Open rapid-action coupling of tank vent line, unclip line and set it aside.
4. Pull engine compartment temperature sensor out of bracket on intake-air distributor and set it aside.
5. Remove support -3- for oil filler pipe and coolant ventilation.
5.1. Unclip coolant ventilation line -1-.
5.2. Unscrew three M6 x 12 outer Torx screws (E10) -2- and remove support.
6. Loosen intake-air distributor 1-3.
6.1. Unscrew six M6 x 35 outer Torx screws (E10). Pull out the screws using a bar magnet to ensure that they are not lost because of the poor accessibility in some areas.
6.2. Tool recommendation for 1/4 inch tool: ratchet spanner, long extension, E10 Torx socket wrench insert.
7. Remove intake-air distributor 1 3 from the engine compartment over the oil filler pipe.
8. Replace moulded seals.
9. The intake-air distributor can be cleaned in a parts washing machine without aggressive cleaning agents.
10. Clean sealing faces on cylinder head.
Removing intake-air distributor - side 4-6
1. Unclip positive crankcase ventilation line -1- out of the support -3- on the intake-air distributor.
2. Loosen intake-air distributor 4-6.
2.1. Unscrew six M6 x 35 outer Torx screws (E10). Pull out the screws using a bar magnet to ensure that they are not lost because of the poor accessibility in some areas.
2.2. Tool recommendation for 1/4 inch tool: ratchet spanner, long extension, E10 Torx socket wrench insert.
3. Remove intake-air distributor 4-6 -2- from the engine compartment.
3.1. Unclip positive crankcase ventilation and turn the retaining clip -1- downwards.
3.2. Lift out intake-air distributor 4 6 past the air conditioning compressor.
4. Replace moulded seals.
5. The intake-air distributor can be cleaned in a parts washing machine without aggressive cleaning agents.
6. Clean sealing faces on cylinder head.
Installation
Tightening sequence:
1. Position screws in tightening sequence and then tighten to the prescribed torque.
Installing intake-air distributor - side 1-3
1. Guide intake-air distributor 1-3 with new moulded seals over the oil filler pipe into the engine compartment and position on the cylinder head.
2. Secure intake-air distributor 1 3.
2.1. Tool recommendation for 1/4 inch tool: ratchet spanner, long extension, E10 Torx socket wrench insert.
2.2. Position the screws using a bar magnet because of the poor accessibility in some areas.
2.3. First position six M6 x 35 outer Torx screws (E10) in tightening sequence and then tighten to the torque specification.
3. Install support -3- for oil filler pipe and coolant ventilation.
3.1. Position three M6 x 12 outer Torx screws (E10) -2- and tighten them to torque.
3.2. Clip in coolant ventilation line -1-.
4. Insert engine compartment temperature sensor into bracket.
5. Clip in tank vent line and insert rapid-action coupling. The plug must lock with an audible click.
5.1. Pull to check that the line is secure.
6. Install generator.
7. Fit drive belt.
Installing intake-air distributor - side 4-6
1. Position intake-air distributor 4 6 with new moulded seals on the cylinder head.
1.1. Turn retaining clip -1- for positive crankcase ventilation downwards before feeding it in.
1.2. Insert intake-air distributor -2-.
1.3. Turn retaining clip into installation position and clip in line.
2. Secure intake-air distributor 4-6.
2.1. Tool recommendation for 1/4 inch tool: ratchet spanner, long extension, E10 Torx socket wrench insert.
2.2. Position the screws using a bar magnet because of the poor accessibility in some areas.
2.3. First position six M6 x 35 outer Torx screws (E10) in tightening sequence and then tighten to the torque specification.
3. Install support -3- for positive crankcase ventilation line -1-.
3.1. Position two M6 x 12 outer Torx screws (E10) -2- and tighten them to torque.
3.2. Clip in vent line.
Subsequent work
WARNING:
Objects or loads falling down
- Risk of squashing or crushing
- Secure components to prevent them from falling down.
1. Slowly raise engine to its installation position using the jack.
2. 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.)
3. Secure cable duct onto the intake distributor.
3.1. Position and tighten M6 x 16 outer Torx screw (E10) -1- at the intake distributor 1 3.
3.2. Position and tighten M6 x 16 outer Torx screw (E10) -1- at the intake distributor 4-6.
4. Install resonance tube.
5. Check for leaks at intake-air distributor.
6. Install air cleaner housing.
7. Connect the battery.