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Intake manifold, removing a fitting

Intake manifold, removing a fitting

To remove


1. Remove the engine protection cover.

2. Remove the air filter housing - see illustration Air filter housing, air control

3. Remove the multi-belt - see Multi-belt, removing and fitting .

4. Undo the lower generator bolt (2).


5. Remove the generator bracket (1) - move back the generator.

6. Remove the intake manifold support (3) from the intake manifold and detach it from the engine block - move the support to one side.

7. Remove the engine ventilation hose (4) from the camshaft cover.


8. Pull the tank vent valve line (1) from the throttle valve connection.

9. Remove the coolant hoses (3) from the throttle valve connection - collect the coolant.

10. remove the coolant line (5) from the intake manifold and the camshaft cover and lay to one side.

11. Remove the brake server vacuum line (2) from the intake manifold.


12. Pull off the cable set connector from the throttle valve connection.

13. Undo or detach the following cable set connectors:

1. tank vent valve
2. camshaft sensor
3. solenoid valve switch throttle
4. Catalytic converter lambda sensor
5. coolant temperature sensor


14. Undo the cable set connector (1) and pull it off from the engine control unit.


15. Undo the knock sensor cable set connector (2).

16. Remove the holder (4) and ground cable (3) from the engine control unit.

17. Remove the bolt (5) from the engine transport bracket.

18. Pull off the connector strip together with the cable duct from the injectors and put them to one side.

19. Lower the fuel pressure using pressure tester 83 94 744 Adapter, fuel pressure gauge via the test connector - collect the fuel that runs out in a suitable container - observe safety regulations and national stipulations.

20. Remove the fuel delivery line (6) from the fuel rail.

21. Undo quick coupling (1) and remove the coolant hose (heating element) (2) - collect the coolant.


22. Remove the engine rear transport bracket (1) from the cylinder head.


23. Unscrew the retaining nuts (2) - remove the intake manifold.

24. When changing the intake manifold: Transfer the components.


To fit


1. Clean the sealing surfaces.

2. Fit the intake manifold together with a new seal and new retaining nuts on the cylinder head - tightening torque 20 Nm.

3. Fit the rear lifting eye onto the cylinder head - tightening torque 25 Nm.

4. Fasten the brake servo vacuum line on the intake manifold.

5. Fit the coolant line onto the intake manifold and camshaft cover - tightening torque 8 Nm.

6. Fit coolant hoses onto throttle body and intake manifold.

7. Fit the coolant hose (heating element).

8. Remove the tank vent valve line from the throttle valve connection.

9. Fit the ground cable and the holder to the engine control unit. Connect the knock sensor cable set connector and fasten it in the holder.

10. Fit and lock the cable set connector for the engine control module.

11. Fit the fuel line on the fuel rail - tightening torque 15 Nm.

12. Fit the contact rail on the injectors - the contact rail should go on with an audible snap.

13. Fit the contact strip retaining screw on the engine transport bracket.

14. Couple or plug in the cables connected to the injector contact rail.

15. Fit the engine vent hose on the camshaft cover.

16. Fit the intake manifold support onto the intake manifold - tightening torque 20 Nm.

17. Pull the intake manifold support off the cylinder head - tightening torque 35 Nm.

18. Fit the generator bracket on the cylinder head, the intake manifold and the generator - tightening torque 20 Nm.

19. Tighten the bottom generator retaining bolt - tightening torque 35 Nm.

20. Fit the multi-belts - see Multi-belt, removing and fitting .

21. Fit the air filter housing - see illustration Air filter housing, air control .

22. Fit the engine cover.

23. Fill and bleed the cooling system - see Cooling system, filling and bleeding and Cooling system, leakage check .