Intake Manifold: Service and Repair
WM 244619 Removing and installing intake-air distributor
Preliminary work
1. Remove engine cover (design cover). -> 108319 Removing and installing engine cover (design cover) Service and Repair
2. Remove oil mist separator. -> 105519 Removing and installing oil mist separator Service and Repair
3. Loosen intake manifold on throttle housing. For details, see -> 243519 Removing and installing air box for throttle housing 243519 Removing and installing air box for throttle housing (Y-shaped pipe ahead of throttle valve)
4. Disconnect ventilation around the intake-air distributor. Naturally aspirated engine => Ventilation on naturally aspirated engines or turbo engine => Ventilation on turbo engines.
Ventilation on naturally aspirated engines
Ventilation on turbo engines
Information
Component overview
Intake module on naturally aspirated engine
Activating variable intake manifold on naturally aspirated engine
Intake air module on turbo engine
Removing intake-air distributor
1. Remove intake-air distributor for naturally aspirated engines.
1.1. Pull off cable plug on pressure sensor of intake-air distributor. For details, see -> 248019 Removing and installing pressure sensor Service and Repair
1.2. Loosen connections on the intake-air distributor.
Intake-air distributor connections at the front
1.2.1. Disconnect cable plug for heat socket.
1.2.2. Disconnect positive crankcase ventilation connection on heat socket.
1.2.3. Disconnect cable plug for throttle housing and remove it from the sheetmetal clip.
1.2.4. Disconnect cable connection for tank vent line on the intake-air distributor.
1.3. Unclip rear fuel tank ventilation line at the wire harness -arrow-. Loosen the front fuel tank ventilation line at the holder. This will allow easy access to the intake-air distributor fastening screws underneath.
Fuel tank ventilation line
1.4. Loosen screws on the intake-air distributor. Illustration shows tightening sequence => Tightening sequence for intake-air distributor (shown on naturally aspirated engine) applies to both naturally aspirated and turbo engines.
Tightening sequence for intake-air distributor (shown on naturally aspirated engine) applies to both naturally aspirated and turbo engines
1.5. Carefully lift the rear intake-air distributor at the shift gate and pull off the vacuum line under the control valve -1- (difficult to reach, use a mirror). Pull off cable plug for the control valve. -2-
Control valve
1.6. Lift off the intake-air distributor.
1.7. Cover intake ducts on the cylinder head to prevent dirt from getting in (using strips of adhesive tape).
2. Remove intake-air distributor for turbo engines in the same way as for naturally aspirated engines. -1, 2, 3 and 4-
Connections on turbo intake module
2.1. Pull off cable plug on pressure sensor of intake-air distributor. For details, see -> 248019 Removing and installing pressure sensor Service and Repair
2.2. Unclip rear fuel tank ventilation line at the wire harness -arrow-. Loosen the front fuel tank ventilation line at the holder. This will allow easy access to the intake-air distributor fastening screws underneath.
Fuel tank ventilation line
2.3. Loosen screws on the intake-air distributor. Illustration shows tightening sequence => Tightening sequence for intake-air distributor (shown on naturally aspirated engine) applies to both naturally aspirated and turbo engines.
Tightening sequence for intake-air distributor (shown on naturally aspirated engine) applies to both naturally aspirated and turbo engines
2.4. Pull off vacuum line. -Unterdruckleitung-
Vacuum line
2.5. Lift off the intake-air distributor.
2.6. Cover intake ducts on the cylinder head to prevent dirt from getting in (using strips of adhesive tape).
Installing intake-air distributor
Information
The tightening specifications for the basic engine are stored centrally. -> 1001IN Tightening torques, tightening sequences, assembly overviews [1][2]Specifications. Tightening torques and assembly instructions for other assemblies (e.g. chassis, electrics, transmission or body) or for peripheral engine equipment can be found in the corresponding documents.
Information
If screws are damaged, take the intake-air distributor off again and carefully tap out the affected screws with a plastic hammer. Carefully tap in new screw elements with a plastic hammer.
1. The intake-air distributor is re-installed in reverse order to removal.
2. Instructions for fitting the intake-air distributor on naturally aspirated engines are as follows:
- Replace intake-air distributor gaskets.
- Move intake-air distributor into installation position. Make sure that the gaskets do not slip out of place and that the lines are not trapped.
- Carefully lift the rear intake-air distributor at the shift gate and connect the vacuum line under the control valve (difficult to reach, use a mirror). Connect cable plug for control valve.
- Carefully screw in screws on intake-air distributor. Screws must all fit easily. Align intake-air distributor with screws tightened slightly and then tighten screws according to the tightening sequence.
Control valve
3. Instructions for fitting the intake-air distributor on turbo engines are as follows:
- Replace intake-air distributor gaskets.
- Move intake-air distributor into installation position. Make sure that the gaskets do not slip out of place and that the lines are not trapped.
- Pull off vacuum line.
- Carefully screw in screws on intake-air distributor. Screws must all fit easily. Align intake-air distributor with screws tightened slightly and then tighten screws according to the tightening sequence.
Vacuum line
Subsequent work
1. Fit ventilation around the intake-air distributor. Naturally aspirated engine => Ventilation on naturally aspirated engines or Turbo engine => Ventilation on turbo engines.
Ventilation on naturally aspirated engines
Ventilation on turbo engines
2. Fit intake manifold on throttle housing. For details, see -> 243519 Removing and installing air box for throttle housing 243519 Removing and installing air box for throttle housing (Y-shaped pipe ahead of throttle valve)
3. Fit oil mist separator. -> 105519 Removing and installing oil mist separator Service and Repair
4. Fit engine cover (design cover). -> 108319 Removing and installing engine cover (design cover) Service and Repair