Intake Manifold: Service and Repair
WM 244619 Removing and installing intake-air distributor
Technical values
Preliminary work
1. Remove engine compartment lid. -> 557819 Removing and installing engine compartment lid - section on "Removing" 557819 Removing and Installing Engine Compartment Lid.
2. Remove resonance tube. -> 247419 Removing and installing resonance tube - section on "Removing" Service and Repair.
2.9-litre engine only:
3. Remove fuel collection pipe with fuel injectors from the relevant intake-air distributor.
-> 243019 Removing and installing fuel collection pipe (with fuel injectors) Service and Repair.
3.1. Unscrew two M6 external Torx screws and remove the fuel connection pipe and fuel injectors.
3.2. Move fuel collection pipe out of the work area.
3.3. The fuel system must not be opened.
Information
Component overview for intake-air distributor
Intake-air distributor components - 2.9-litre engine
Overview of 2.9-litre intake system
Distinguishing features compared with intake-air distributor on 3.4-litre engine
Overview of 3.4-litre intake system
Screw position of external Torx screw (E10, M6 x 35) -1 to 12-.
Tightening sequence for intake-air distributor
Removal
Removing intake-air distributor for cylinder bank 1-3
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. Unscrew external Torx screw (E10, M6 x 16) -2- used to secure the cable duct -1- to the intake-air distributor for cylinder bank 1-3.
Wire harness mounting, cylinder bank 1-3
2. Remove holder air-conditioning lines.
2.1. Screw off fastening nut -1- , open the holder -2- and remove the rubber sleeve -3-.
2.2. The metal holder remains on the intake-air distributor for cylinder bank 1-3.
Loosening holder for refrigerant lines
3. Slide engine compartment temperature sensor on the intake-air distributor for cylinder bank 1-3 with the rubber sleeve out of the mounting and leave it hanging at the wire harness.
4. Remove intake-air distributor for cylinder bank 1-3.
4.1. Unscrew six external Torx screws (E10, M6 x 35). Tool recommendation - 1/4 inch tool: ratchet, long extension, E10 Torx socket-wrench insert.
4.2. To avoid loosing the screws when working in difficult-to-reach areas, remove them using a bar magnet.
4.3. Press the cable duct aside slightly and remove the intake-air distributor by lifting it upwards.
4.4. Dispose of old moulded seals and clean sealing faces.
5. Cover intake openings or seal them with adhesive tape.
Removing intake-air distributor for cylinder bank 4-6
1. Loosen cable duct -2- on intake-air distributor for cylinder bank 4-6.
1.1. To do this, unscrew external Torx screw (E10, M6 x 12) -1- and move holder and wire harness aside.
Cable duct mounting on intake-air distributor 4-6
2. Pull off line for positive crankcase ventilation -1- at the oil separator, then unclip it and lay it aside.
2.1. Unclip tank vent valve -2- and lines at the intake-air distributor and set them aside.
Positive crankcase ventilation, tank ventilation, cable duct on cylinder bank 4-6
3. Remove intake-air distributor for cylinder bank 4-6.
3.1. Unscrew six external Torx screws (E10, M6 x 35). Tools: 1/4-inch ratchet, long extension, E10 Torx socket-wrench insert.
3.2. To avoid loosing the screws when working in difficult-to-reach areas, remove them using a bar magnet.
3.3. Press the cable duct aside slightly and remove the intake-air distributor by lifting it upwards.
3.4. Dispose of old seals and clean sealing faces.
4. Cover intake openings or seal them with adhesive tape.
Installing intake-air distributor for cylinder bank 1-3
1. Position intake-air distributor for cylinder bank 1-3 with new moulded seals on the cylinder head.
1.1. Be careful of the seals.
2. Fit intake-air distributor for cylinder bank 1-3.
2.1. 1/4 inch tool: torque wrench, long extension, Torx socket-wrench insert (E10).
2.2. Position screws using a bar magnet.
2.3. Tighten six external Torx screws (E10, M6 x 35) uniformly.
2.4. Tighten screws according to the specified tightening sequence and torque.
=> Tightening torque: 13 Nm (9.5 ftlb.)
3. Secure cable duct -1- to the intake-air distributor for cylinder bank 1-3 using an external Torx screw (E10, M6 x 12).
=> Tightening torque: 13 Nm (9.5 ftlb.)
Wire harness mounting, cylinder bank 1-3
4. Fit holder for air-conditioning lines.
4.1. Fit rubber sleeve -3-.
4.2. Fit retaining clip -2- , screw on fastening nut -1- and tighten carefully by hand.
Securing holder for refrigerant lines
5. Fit engine compartment temperature sensor with rubber sleeve on intake-air distributor.
Installing intake-air distributor for cylinder bank 4-6
1. Position intake-air distributor for cylinder bank 4-6 with new moulded seals on the cylinder head.
1.1. Be careful of the seals.
2. Fit intake-air distributor for cylinder bank 4-6.
2.1. Tool recommendation - 1/4 inch tool: torque wrench, long extension, Torx socket-wrench insert (E10).
2.2. Position screws using a bar magnet.
2.3. Tighten six external Torx screws (E10, M6 x 35) uniformly.
2.4. Tighten screws according to the specified tightening sequence and torque.
=> Tightening torque: 13 Nm (9.5 ftlb.)
3. Secure cable duct -2- to the intake-air distributor for cylinder bank 4-6 using an external Torx screw (E10, M6 x 12).=> Tightening torque: 13 Nm (9.5 ftlb.)
Cable duct mounting on intake-air distributor 4-6
4. Fit positive crankcase ventilation line -1- and tank vent line -2-.
Positive crankcase ventilation, tank ventilation, cable duct on cylinder bank 4-6
Subsequent work
2.9-litre engine only:
1. Install fuel collection pipe with fuel injectors.
-> 243019 Removing and installing fuel collection pipe (with fuel injectors) Service and Repair.
All engines:
2. Install resonance tube. -> 247419 Removing and installing resonance tube - section on "Installing" Service and Repair.
3. Install engine compartment lid. -> 557819 Removing and installing engine compartment lid - section on "Installing" 557819 Removing and Installing Engine Compartment Lid.