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Intake manifold, lower part

Intake manifold, lower part

To remove

Warning

Dismantling the fuel rails involves working on the car's fuel system. The following points must therefore be observed in connection with the work:



• Make provision for good ventilation! If approved ventilation for extracting fuel fumes is available then it must be used.

• Use protective gloves! Prolonged contact with fuel may irritate the skin.

• Keep a class BE fire extinguisher close at hand! Watch out for sparks, e.g. in connection with breaking electric circuits, short-circuits, etc.

• Smoking is absolutely forbidden.



1. Remove the engine cover and the turbocharger delivery pipe (2 screws under the wiring harness). Plug the hoses.


2. Detach the air hose from the intake manifold, bend it to one side and plug it.

3. Disconnect all the cables connected to the wiring harness channel and cut all the securing points. Remove the channel from the cylinder head and lay it over the engine.

4. Detach the vacuum hose from the EGR valve.

5. Note the position of the fuel rails and their clips and mark the pipes.


6. Remove the fuel return hoses from the cylinder head.

7. Remove the fuel rails (remove the fuel rail clips if necessary).

8. Slightly loosen the fuel connections on the fuel pump.

9. Remove the upper part of the intake manifold.


If the upper part of the intake manifold is to be changed then the pressure sensor and EGR valve must be removed.

10. Pull off the vacuum hose from the control valve's vacuum unit.


11. Remove the lower part of the intake manifold.

If the lower part of the intake manifold is to be changed, the vacuum valve and crankshaft position sensor bracket must be removed.


To fit



1. Clean the sealing surfaces.

2. Fit a new gasket on the cylinder head and fit the lower part of the intake manifold with new nuts.

Tightening torque 20 Nm (15 lbf ft).

3. Fit the vacuum valve and the bracket for the crankshaft position sensor connector if the intake manifold has been changed.

4. Connect the vacuum hose to the control valve's vacuum unit.

5. Clean the sealing surfaces.


6. Fit a new gasket to the lower part of the intake manifold and fit the upper part of the intake manifold.

Tightening torque 10 Nm (7 lbf ft).

7. Fit the pressure sensor and EGR valve if the intake manifold has been changed.

8. Tighten the fuel lines on the fuel pump.


Tightening torque 25 Nm (18.5 lbf ft).

9. Check the fuel rail connecting cones and replace as necessary.

10. Attach the fuel rails with the clips in their original positions.

Tightening torque 25 Nm (18.5 lbf ft).

11. Check the condition of the fuel return hoses and joints, and replace as necessary.

12. Connect the fuel return hoses.

13. Connect the vacuum hose to the EGR valve.


14. Fit the wiring harness channel to the engine.

15. Secure the wiring harness as it was previously.

Important

To reduce the risk of hoses mounted on the delivery side of the turbocharger coming loose due to low friction at high air pressures, the hoses and connecting pieces must be cleaned thoroughly before fitting. Use a rag dampened with 30 15 815 Cleaning agent to wipe clean inside the ends of the hoses. Clean also the connecting pieces. If hose clips are rusty or damaged, they must be replaced with new ones to maintain the correct clamping force.


16. Refit the hose to the intake manifold.

17. Refit the turbocharger delivery pipe and the engine cover.