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Intake manifold, upper and lower sections, V6

Intake manifold, upper and lower sections, V6

To remove

Warning

Removal of the fuel rail involves partial dismantling of the car's fuel system. The following points must therefore be observed in connection with this work:

• Make sure a class BE fire extinguisher is close to hand! Consider the risk of sparking, e.g. when breaking circuits, short-circuits etc.

• Absolutely No Smoking!

• Ensure that there is a good exchange of air. If approved ventilation for the extraction of fuel fumes is available, this should be used.

• Wear protective gloves! Prolonged exposure of the hands to fuel can cause irritation to the skin.

• Wear protective goggles.



1. Remove the intake manifold from the mass air flow sensor to the turbocharger.


2. Remove the upper engine cover.

3. Unplug the connectors, remove the front cable rail and move aside the engine harness.

4. Remove the upper intake manifold and the turbocharger's bracket.


5. Remove the fuel pipes and fuel rail.


6. Remove the EGR valve and coolant hose. Undo the water-cooled EGR pipe and the pipes to the turbo and water jacket and move them aside.


7. Remove the crankcase ventilation pipe from the timing cover.


8. Remove the lower intake manifold from the rear and front cylinder banks.


To fit


1. Clean the sealing surfaces and fit the intake manifold with new gaskets.

Tightening torque, lower intake manifold 31 Nm (23 lbf ft)


2. Fit the crankcase ventilation pipe to the timing cover. Use a new O-ring.

3. Fit the EGR valve water jacket pipe and the EGR valve with pipe clamp. Use new gaskets.

4. Fit the loose bracket between the water pipe and the rear bank intake manifold and the pipe to the turbocharger with new gaskets.


5. Plug in the connector to the pressure sensor and position the cables.

6. Fit the fuel rail and fuel pipes. Make sure the protective sock is fitted on the connector.

Tightening torque: 25 Nm (18 lbf ft)


7. Fit the bracket for the turbocharger.

8. Fit the upper intake manifold with new seals. Fit the front cable rail and engine harness.

Tightening torque: 21 Nm (15 lbf ft)


Important

To reduce the risk of hoses mounted on the delivery side of the turbocharger coming loose due to low friction at high air pressure, the hoses and connecting pieces must be cleaned thoroughly before fitting. Use a rag dampened with 93 160 907 Motip Dupli cleaning agent to wipe clean inside the ends of the hoses. Clean the connecting pieces as well. If hose clips are rusty or damaged, they must be replaced so the correct clamping force is maintained.


9. Fit the turbocharger delivery hose to the upper intake manifold.

10. Replace the upper engine cover.


11. Fit the intake manifold between the mass air flow sensor and the turbocharger.

Tightening torque, mass air flow sensor: 3.5 Nm (2.5 lbf ft)