Intake Manifold: Service and Repair

Intake Manifold

Requirements:

Vehicles with Engine Code BKW:

• Fuel filter unit is removed. Refer to => [ Fuel Filter ] Removal and Replacement.

Vehicles with Engine Code BWF:

• Bypass flap with cooler for Exhaust Gas Recirculation (EGR) is removed. Refer to => [ Bypass Flap with EGR Cooler ] Service and Repair.

Continuation for all Vehicles:

• The upper oil filter housing is removed. Refer to => [ Oil Filter Housing Overview ] Description and Operation.

• The components illustrated here are for cylinder bank 2. They are a mirror image of the components for cylinder bank 1.

• In order to be able to remove the intake manifold without disassembling the fuel rail, the intake manifold bolts must be completely removed.






1 Cylinder Head

• Removing and installing, refer to => [ Cylinder Heads ] Cylinder Heads.

2 Gasket

• Always replace.

3 Intake Manifold

Intake connection overview:

• Vehicles with engine code BKW, refer to => [ Intake Connection Overview ] Description and Operation.

• Vehicles with engine code BWF, refer to => [ Intake Connection Overview ] Description and Operation.

4 Bolt

• 20 Nm

5 Fuel Rail

6 Bolt

• 8 Nm + 90° (1/4) additional turn.

• Always replace.

7 Seal

• Always replace.

8 Connecting Piece

• Long

• For the supply.

• Remove and install using the flat headed pliers (VAS 6275).

9 Connecting Piece

• Short

• For the return.

• Remove and install using flat headed pliers (VAS 6275).

10 Glow Plug

• 15 Nm

Cylinder bank 1:

• Glow plugs 1 through 5 (Q10...Q14).

Cylinder bank 2:

• Glow plugs 6 through 10 (Q15...Q19).

Removing and installing, checking, refer to => [ Ceramic Sheathed Element Glow Plugs ] Service and Repair.