Intake Manifold: Service and Repair
WM 244619 Removing and installing intake-air distributor
Preliminary work
Preliminary work for naturally aspirated engines
1. Remove engine cover (design cover). -> 108319 Removing and installing engine cover (design cover) - section on "Removing" 108319 Removing and installing engine cover (design cover).
2. Remove oil mist separator. -> 105519 Removing and installing oil mist separator Service and Repair
3. Loosen intake port on throttle housing. -> 243519 Removing and installing air box for throttle housing 243519 Removing and installing cowl for throttle housing (Y-pipe)
4. Disconnect ventilation lines at the intake-air distributor => Ventilation on naturally aspirated engines.
Ventilation on naturally aspirated engines
Removing intake-air distributor
Removing intake-air distributor on naturally aspirated engines
Intake module on naturally aspirated engine
1. Loosen connections on the intake-air distributor.
Intake-air distributor connections at the front
1.1. Release and pull off electric plug connection on the heat socket -1-.
1.2. Disconnect hose connection -2- for positive crankcase ventilation on heat socket.
1.3. Release and unplug electric plug connection on the throttle housing -3- , then loosen the sheetmetal clip.
1.4. Disconnect cable connection for tank vent line on the intake-air distributor. ???
2. Release and unplug electric plug connection on the pressure sensor -4-.
3. Loosen screws on the intake-air distributor. Illustration shows tightening sequence => Tightening sequence for intake-air distributor.
Tightening sequence for intake-air distributor
4. 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). Release and unplug electric plug connection for the control valve -2-.
Control valve
5. Lift off intake-air distributor.
6. Cover intake ducts on the cylinder head to prevent dirt from getting in (using strips of adhesive tape for example).
Installing intake-air distributor
Installing intake-air distributor on naturally aspirated engines
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 installed in reverse order to removal.
2. Instructions for fitting the intake-air distributor:
- Replace gaskets on the intake-air distributor.
- 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). Plug in electric plug connection for the 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
Tightening sequence for intake-air distributor
Subsequent work
Subsequent work for naturally aspirated engines
1. Secure ventilation lines at the intake-air distributor => Ventilation on naturally aspirated engines.
Ventilation on naturally aspirated engines
2. Install oil mist separator. -> 105519 Removing and installing oil mist separator Service and Repair
3. Secure intake port on throttle housing. -> 243519 Removing and installing air box for throttle housing (Y-shaped pipe) - section on "Installing" 243519 Removing and installing cowl for throttle housing (Y-pipe)
4. Install engine cover (design cover). -> 108319 Removing and installing engine cover (design cover) - section on "Installing" 108319 Removing and installing engine cover (design cover).