Intake manifold, upper part
Intake manifold, upper part |
To remove |
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Make provision for good ventilation! If approved ventilation for extracting fuel fumes is available then it must be used.
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Use protective gloves! Prolonged contact with fuel may irritate the skin.
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Keep a class BE fire extinguisher close at hand! Watch out for sparks, e.g. in connection with breaking electric circuits, short-circuits, etc.
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Smoking is absolutely forbidden.
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1. |
Remove the engine cover and the turbocharger delivery pipe (2 screws under the wiring harness). Plug the hoses.
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2. |
Detach the air hose from the intake manifold, bend it to one side and plug it.
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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.
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4. |
Detach the vacuum hose from the EGR valve.
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5. |
Note the position of the fuel rails and their clips and mark the pipes.
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6. |
Remove the fuel return hoses from the cylinder head.
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7. |
Remove the fuel rails (remove the fuel rail clips if necessary).
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8. |
Slightly loosen the fuel connections on the fuel pump.
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9. |
Remove the upper part of the intake manifold.
If the lower part of the intake manifold is to be changed then the pressure sensor and EGR valve must be removed. |
To fit |
1. |
Clean the sealing surfaces.
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2. |
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). |
3. |
Fit the pressure sensor and EGR valve if the intake manifold has been changed.
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4. |
Tighten the fuel lines on the fuel pump.
Tightening torque 25 Nm (18.5 lbf ft). |
5. |
Check the fuel rail connecting cones and replace as necessary.
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6. |
Attach the fuel rails with the clips in their original positions.
Tightening torque 25 Nm (18.5 lbf ft). |
7. |
Check the condition of the fuel return hoses and joints, and replace as necessary.
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8. |
Connect the fuel return hoses.
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9. |
Connect the vacuum hose to the EGR valve.
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10. |
Fit the wiring harness channel to the engine.
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11. |
Secure the wiring harness as it was previously.
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12. |
Refit the hose to the intake manifold.
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13. |
Refit the turbocharger delivery pipe.
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14. |
Fit the engine cover.
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