Intake Manifold, Removing and Installing
Intake Manifold, Removing And Installing
- Pull lock carrier forward.
- Disconnect connector -5- at Charge air pressure sensor -G31-.
- Unfasten hose clamps -3- and -4-.
- Remove hoses at air recirculation valves.
- Remove bolts -1- and -2- and disconnect air pipe.
- Remove vacuum hose (arrow) to brake servo.
- Disconnect connector (arrow) at Engine Coolant Temperature (ECT) sensor -G2-/-G62-.
NOTE: The following illustrations show a view from the rear with the engine removed.
- Disconnect connector (arrow) at Camshaft Position (CMP) sensor 2 -G163-.
- Disconnect connector -3- at Wastegate bypass regulator valve -N75-.
- Remove hose -2- at valve.
- Disengage valve -5- at holder.
- Remove bolts -1- and -4-.
- Remove secondary air system hoses at locations marked by arrows.
- Remove secondary air inlet pipes.
- Remove bolts -1- and -2-.
- Remove crankcase breather hose on left at location marked by arrow.
NOTE: Leave pipe hanging loosely from engine.
- Remove out bolts -1 ... 3-.
- Remove crankcase breather hose on right at location marked by arrow.
- Screw out bolt -1-.
- Detach crankcase breather hose on right at location marked by -arrow-.
NOTE: Illustration shows view from rear with engine removed.
- Remove crankcase breather hoses at locations marked by arrows.
NOTE: Mark installation position of all cable ties before disconnecting engine wiring harness from fuel rail.
- Cut open all cable ties at engine wiring harness.
- Disconnect connectors at both cylinder heads to:
1 Injectors -N30- ... -N86- (8x)
2 Ignition coils -N- ... -N191- (8x)
- Disconnect connectors at:
1 Knock sensor 1 -G61-
2 Secondary air injection solenoid valve -N112-
3 Gray connector to Recirculation valve for turbocharger -N249- (adapter)
4 Green connector to electric coolant pump
5 Knock sensor 3 -G198-
6 Intake Air Temperature (IAT) sensor -G42-
7 Knock sensor 2 -G66-
8 Recirculating valve for turbocharger -N249-
- Disconnect connector (arrow) at Camshaft Position (CMP) sensor -G40-.
- Disconnect connector (arrow) at Throttle valve control module -J338-.
- Disconnect connector (arrow) at Valve -2- for camshaft adjustment -N208-.
- Unscrew two interference suppression capacitors on left and right of intake manifold (arrow).
- Disconnect connectors at:
1 Oil level thermal sensor -G266-
2 Left Electro-Hydraulic engine mount solenoid valve -N144-
- Lift engine wiring harness off engine and move it to rear.
- Disconnect vacuum hoses at locations marked by arrows.
- Lay bare vacuum hoses.
- Disconnect Secondary air injection solenoid valve -N112- item -1- and Recirculating valve for turbocharger -N249- item -2- from holder.
WARNING: Fuel system is pressurized. Wrap a cloth around the joint before opening the system. Then dissipate pressure by carefully unfastening the joint.
- Disconnect fuel supply pipe -2- and fuel return pipe -1-.
- Detach vacuum hose -1- to fuel pressure regulator.
- Unscrew fuel rail (arrows) and remove together with injectors from intake manifold.
- Remove coolant hose -1- and vacuum hose -2-.
- Unfasten bolted joints in sequence 20 ...1.
- Swivel intake manifold aside.
- Remove coolant hose (arrow) at electric coolant pump.
- Remove intake manifold.
Installing
Install in reverse order, paying attention to the following:
NOTE:
- Replace gaskets and O-rings.
- Secure all hose connections with standard hose clamps.
- Hose connections and hoses for charge air system must be free from oil and grease before installing. Never use lubricant.
- Tighten bolted joints in sequence 1... 20.
- Install lock carrier with attachments.
Tightening torques
Component Nm
Intake manifold to cylinder heads 10
Rear air pipe to intake manifold 40
Fuel rail to intake manifold 10
Fuel supply pipe to fuel rail 25
Crankcase breather pipe to engine 10
Front air Throttle valve assembly 10
duct to Holder 10 1)
Clamps for air hoses 5
1) Apply locking fluid when installing