Removing and Installing Intake Manifold

Removal and Installation of Intake Manifold Upper and Lower Part, Renewing Gaskets:

Removal:










1 Disconnect battery.
2 Partially drain coolant. Service and Repair
3 Unscrew injection lines and fuel lines. Catch fuel with a rag.
Close fuel lines blind.
4 Pull off auxiliary air lines.
5 Force off Bowden wire for automatic transmission.
6 Unscrew bearing bracket for guide block control.
7 Unscrew bearing bracket for longitudinal regulating shaft.
8 Pull off all connecting cables and plug connections.
9 Pull off vacuum line for automatic transmission and unscrew for brake unit.
10 Loosen and pull off coolant hoses.
11 Unscrew all fastening screws and remove intake manifold toward the rear.
12 Clean intake manifold and check flange surfaces with straightedge, level on surface plate, if required.

Installation:

13 Mount intake manifold in vice versa sequence with new gaskets.
Intake manifold gaskets are not graphited. Do not mix up graphited intake manifold gaskets of grey iron engine with those on light-alloy engine.
14 Adjust regulating linkage.
15 Connect battery.
16 Fill in coolant. Service and Repair
17 Run engine, check fuel lines for leaks. Check intake system. fuel distributor and injection valves for leaks by spraying with Iso-Oktan.
18 Adjust idle speed.

Intake Manifold:

1 Contour hose
2 Spring hose clamps
3 Auxiliary air valve
3a Gasket
4 Contour hose
5 Idle speed air distributor
6 Gasket
7 Cold start valve
8 Contour hose
9 Auxiliary air line
10 Intake manifold upper halt
11 Closing plug
12 Gasket
13 Throttle valve housing
14 Gasket
15 Hex. socket screw
16 Washer
17 Rubber connection
18 Intake manifold lower halt
19 Spacing sleeve
20 Washer
21 Hex. socket screw
22 Closing plug
22a Sealing ring
23 Idle speed adjuster
24 Double thread connection
25 Sealing ring
26 Air feed for injection valves
27 Sealing ring
28 Connection for automatic transmission