Intake Manifold: Service and Repair
WM 244619 Removing and installing intake-air distributor - Turbo
Tools
Technical values
Preliminary work
1. Remove air cleaner housing.
=> 242519 Removing and installing air cleaner housing - Turbo.
2. Remove tailpipe covers.
=> 263519 Removing and installing tailpipe cover - Turbo.
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.
Information
- When lowering, the engine must not rest on the rear axle cross member.
3. Lower the engine.
3.1. Support the engine at the oil pan using the hydraulic jack HH2 WE 1033 and transmission jack plate of transmission jack V.A.G 1383 A WE 1082.
3.2. Alternative to transmission jack plate:
Screw on the mounting peg 9163/2 in the middle using a wooden board (40 x 30 cm) and use it as a support.
Mounting peg
3.3. Loosen two M12 special nuts (internal Torx, screw insert T55) -1- on the engine mounting (hydraulic mount) at the left and right.
Engine carrier to engine mounting on cylinder bank 4-6 (view from below)
3.4. Slowly lower the engine by about 40 mm (measured at the engine carrier) using the hydraulic car jack.
Removing intake-air distributor
Component overview 1:
Component overview of intake-air distributor 1
Component overview 2: Intake-air distributor disassembled
Component overview of disassembled intake-air distributor
1. Disconnect crankcase vent line, support elements on the intake-air distributor and cable plug for electronic accelerator.
1.1. Disconnect crankcase vent line -1-.
1.2. Remove strut -2- by unscrewing two external Torx screws (E10, M x 12) -3-.
1.3. Remove throttle housing support by loosening one M6 hexagon nut -4-.
1.4. Pull off cable plug -5- for electronic accelerator.
Peripheral elements on centre intake-air distributor
2. Remove centre part of intake-air distributor.
Removing centre part of intake-air distributor
2.1. Open bayonet sleeves -2- for the centre part in -direction of arrow-.
2.2. View with inner locking lug open -arrow-.
Bayonet lock open
2.3. Disconnect vacuum lines -3 and 4- on the back and remove centre part.
3. Replace all seals (see component overview).
Installing intake-air distributor
Information
Always replace gaskets and O-rings.
- Grease all gaskets (except for the cooling system) with Kluber Syntheso Glep (Part No. 000.043.204.68).
1. Lightly grease sealing rings with the prescribed lubricant.
2. Install centre part of intake-air distributor.
2.1. Fit centre part and connect vacuum lines -3 and 4-.
2.2. Position bayonet sleeves -2- at the sides of the intake-air distributors and close them -direction of arrow-.
Installing centre part of intake-air distributor
3. View of bayonet sleeve (outer locking lug) in closed position -arrow-.
Bayonet lock closed
4. Secure support elements for intake-air distributor and plug in cable plug for electronic accelerator and positive crankcase ventilation line.
4.1. Secure throttle housing support by tightening one M6 hexagon nut -4-.
=> Tightening torque: 6 Nm (4.5 ftlb.)
4.2. Plug in cable plug -5- for electronic accelerator.
4.3. Fit strut -2- for intake-air distributor. Tighten two external Torx screws (E10, M6 x 12) -3-.
=> Tightening torque: 10 Nm (7.5 ftlb.)
4.4. Connect positive crankcase ventilation line -1-.
Peripheral elements on centre intake-air distributor
Subsequent work
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.
Information
- When lowering, the engine must not rest on the rear axle cross member.
1. Raise the engine.
1.1. Support the engine at the oil pan using the hydraulic jack HH2 WE 1033 and transmission jack plate of transmission jack V.A.G 1383 A WE 1082.
1.2. Alternative to transmission jack plate:
Mounting peg
Screw on the mounting peg 9163/2 in the middle using a wooden board (40 x 30 cm) and use it as a support.
=> Mounting peg
1.3. Slowly lift the engine with the hydraulic jack.
Engine carrier to engine mounting on cylinder bank 4-6 (view from below)
1.4. Tighten two special M12 nuts (internal Torx, screw insert T55) -1- on the engine mounting (hydraulic mount) at the left and right.
=> Tightening torque: 85 Nm (63 ftlb.)
2. Install tailpipe covers.
=> 263519 Removing and installing tailpipe cover - Turbo.
3. Install air cleaner housing.
=> 242519 Removing and installing air cleaner housing - Turbo.