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Intake manifold, upper and lower sections

Intake manifold, upper and lower sections

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 upper engine cover and charge air pipe (2 bolts under wiring harness). Cut the cable tie and plug the hoses.


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

3. Unplug the timing sensor, temperature sensor and EGR valve. Cut the cable tie.


4. Remove the cable duct from the camshaft cover and throttle body. Place the cable duct over the engine.

5. Remove the throttle body.

6. Remove the engine wiring harness from the oil filter housing.

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


8. Remove the fuel return hoses from the fuel bridges.

9. Remove the fuel rails and clamps. Remove in the order of the cylinders.

10. Release any pressure in the cooling system by undo the expansion tank cap.

11. Clamp the coolant hoses to the EGR valve with 30 07 739 Pinch-off pliers . Disconnect the hoses from the valve.


12. Remove the upper part of the intake manifold.

13. Remove the swirl throttle vacuum unit.


14. Remove the lower intake manifold.


To fit


1. Clean the sealing surfaces.

2. Refit the swirl throttle vacuum unit.


3. Fit a new gasket and fit the lower section of the intake manifold.

Tightening torque: 20 Nm (15 lbf ft)

Tighten the bolts securing the vacuum unit.

4. 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).


5. Fit the fuel lines with clips to the cylinder head and fuel pump. Check the fuel rail connecting cones and replace if necessary.

Tightening torque 25 Nm (19 lbf ft)

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

7. Connect the coolant hoses to the EGR valve.

8. Fit new fuel return hoses. Check the condition of the T-pieces and change if necessary.

9. Fit the lower clip that secures the wiring harness to the oil filter housing.


10. Fit the throttle body.

11. Plug in the timing sensor, temperature sensor and EGR valve.

12. Secure the wiring harness as it was previously and tighten the bolts.

13. Fit the hose to the intake manifold.


14. Fit the charge air pipe and secure the engine wiring harness with a cable tie.

15. Press the cable duct into place.

16. Connect 30 31 069 Nipple, bleeding equipment to 88 19 096 Bleeding equipment or equivalent and start the suction device.


17. Remove the end cap and connect the nipple to the service outlet on the fuel pump feed line.

18. Suck until a constant flow of fuel is seen in the suction line to the brake bleeding tool.

19. Remove the bleed nipple from the service outlet while it is still sucking (to avoid fuel spillage and air entering the system).

20. Put on the end cap for the service outlet.

21. Fit the upper engine cover.