244619 Removing and installing intake-air distributor
WM 244619 Removing and installing intake-air distributor
Tools
Technical values
Preliminary work
1. Disconnect 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 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.
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.
4. Slowly lower the engine approximately 15 mm using the jack.
5. Remove resonance tube.
=> 247419 Removing and installing 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.
Screw for cable duct 1-3
6.2. Unscrew M6 x 16 outer Torx screw (E10) -1- at the intake distributor 4-6.
Screw for cable duct 4-6
Information
Component overview for intake-air distributor
Component overview
Overview of intake-air distributor
Overview of screws
Tightening specification
Removal
Removing intake-air distributor - side 1-3
1. Release drive belt.
=> 137819 Removing and installing drive belt.
2. Remove generator.
=> 272219 Removing and installing 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.
Support for oil filler pipe, vent line
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.
Positive crankcase ventilation line support
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.
Intake-air distributor, side 4-6
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.
Tightening specification
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-.
Support for oil filler pipe, vent line
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.
=> 272219 Removing and installing generator.
7. Fit drive belt.
=> 137819 Removing and installing 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.
Intake-air distributor, side 4-6
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.
Positive crankcase ventilation line support
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.
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
3.2. Position and tighten M6 x 16 outer Torx screw (E10) -1- at the intake distributor 4-6.
Screw for cable duct 4-6
4. Install resonance tube.
=> 247419 Removing and installing resonance tube.
5. Check for leaks at intake-air distributor.
6. Install air cleaner housing.
=> 242519 Removing and installing air cleaner housing.
7. Connect the battery.
=> 2X00IN02 Work instructions after disconnecting the battery.