Intake Air Plenum: Service and Repair
WM 247419 Removing and installing resonance tube
Tools
Technical values
Preliminary work
1. Disconnect the battery.
2. Remove air cleaner:
=> 242519 Removing and installing air cleaner housing.
3. Remove throttle housing.
=> 244219 Removing and installing throttle 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.
4. 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.
4.1. 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.
Engine carrier at engine mounting on side 4-6 (view from below)
Information
- When lowering, the engine must not rest on the rear axle cross member.
5. Slowly lower the engine approximately 15 mm using the jack.
6. Release cable duct from the intake distributor on side 1-3.
6.1. Unscrew the M6 Torx screw -1- at the intake distributor 1-3 to create better access to the left clamp.
Screw for cable duct 1-3
Removal
Removing resonance tube
Component overview
Resonance tube components
1. Detach positive crankcase ventilation lines -2 and 3- and tank vent connection -1- from resonance tube.
Positive crankcase ventilation and tank vent line
2. Remove clamps -1- from resonance tube.
2.1. Unscrew two M6 inner Torx screws -2- , detach upper parts of clamps and remove them.
Securing resonance tube
2.2. Press lower parts of clamps downwards and pull them out.
2.3. The screws are micro-self-locking and must be replaced.
3. Remove resonance tube.
3.1. Move rubber sleeves -2- inwards using a plastic spatula -1-. To do this, lift rubber sleeve using the plastic spatula -arrow- and push onto the resonance tube by hand.
Moving rubber sleeves
3.2. On the 3.8-litre engine also pull off a vacuum line and a cable plug from the control valve of the tuning flap.
Tuning flap control on 3.8-litre engine
3.3. Pull the resonance tube out to the rear.
4. Clean the inside of the resonance tube (oil film) with a clean, lint-free cloth.
4.1. Pay close attention to the tuning flap on the 3.8-litre engine.
4.2. Clean the inside of the intake-air distributor likewise as far as possible.
Installation
Installing resonance tube
1. Pre-position resonance tube between intake-air distributors.
1.1. On the 3.8-litre engine connect a vacuum line and a cable plug onto the control valve of the tuning flap.
2. Fit rubber sleeves on both sides.
2.1. Lightly spray resonance tube and intake distributors at the seat of the rubber sleeve with silicone spray.
2.2. Position rubber sleeves on the upper side between the resonance tube and the intake-air distributor with the stop bead.
2.3. To ensure that the rubber sleeves are seated correctly all around, pull them through 360 degrees along the contour of the resonance tube.
Important: the stop bead must be seated between the resonance tube and intake distributor.
3. Insert lower halves of clamps with the connecting hooks pointing in the direction of travel and wedge them into the particular sleeve groove.
3.1. To do this, pull up the clamp half at the front and rear at the same time until it is seated automatically.
4. Engage the eye of the upper halves of the clamps -1- in the connecting hooks and fix in place at the rear (in direction of travel) using new M6 x 35 countersunk screws -2-.
Securing resonance tube
5. Check that the resonance tube and the rubber sleeves are seated correctly.
5.1. Screw down both screws to the prescribed torque.
6. Connect positive crankcase ventilation lines -2 and 3- and tank vent connection -1- onto resonance tube.
Positive crankcase ventilation and tank 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.
Engine carrier at engine mounting on side 4-6 (view from below)
=> Tightening torque: 85 Nm (63 ftlb.)
3. Secure cable duct onto the intake distributor on side 1-3.
3.1. Position and tighten M6 x 16 outer Torx screw (E10) -1- at the intake distributor 1-3.
Screw for cable duct 1-3
=> Tightening torque: 13 Nm (9.5 ftlb.)
4. Install throttle housing.
=> 244219 Removing and installing throttle housing.
5. Check for leaks at intake-air distributor.
6. Install air cleaner.
=> 242519 Removing and installing air cleaner housing.
7. Connect the battery.
=> 2X00IN02 Work instructions after disconnecting the battery.