Removal and installation the intake manifold
Removal the intake manifold
1. Disconnect the negative battery terminal.
2. Remove the air filter unit.
3. Loosen the bolt (1) securing the oil filler neck.
4. Remove the oil filler neck.
5. Disconnect the oil vapor ventilation pipe (2).
6. Disconnect the brake booster vacuum line (3).
7. Disconnect the gasoline vapor ventilation pipe (4).
8. Disconnect the intake manifold vacuum sensor connector (5).
9. Disconnect the intake air temperature sensor connector (6).
10. Disconnect the fuel injector connectors.
11. Disconnect the throttle valve connector.
Caution: When working with fuel cells, do not smoke or allow open flames in the work area. Since fuel may leak when disconnecting fuel line connectors, take steps to protect surrounding components from fuel spillage.
12. Disconnect the fuel supply line from the fuel rail (7).
13. Disconnect the spark plug wires (8).
Caution: When disconnecting spark plug wires, pull on the connectors, not the wires.
14. Remove the fuel rail.
15. Disconnect the spark plug high-voltage wires and the oil dipstick from the intake manifold.
16. Disconnect the power terminal (11) from the starter.
17. Unscrew the bolts (12) of the intake manifold from the rocker cover.
18. Unscrew the bolts (13) of the intake manifold from the cylinder head.
19. Remove the throttle valve with the accumulation chamber assembly.
20. Remove the intake manifold gasket.
Installing the intake manifold
Note: Replace the intake manifold gasket with a new one after each removal.
Caution: To ensure proper sealing, the sealing surfaces must be clean, dry and free of grease (avoid any fingerprints).
1. Using a cleaning agent, clean and degrease the contact surfaces between the intake manifold and the cylinder block, as well as between the intake manifold and the rocker cover.
2. Install the intake manifold with a new gasket.
3. Apply LOCTITE FRENETANCH to the intake manifold to cylinder head bolts.
4. Tighten all intake manifold bolts to 6 Nm.
5. Tighten the intake manifold bolts in the sequence shown in the figure to a torque of 10 N·m.
6. Further installation is carried out in the reverse order of removal.
Note: When installing high voltage spark plugs, it is necessary to apply a bead of FLUORINATED GREASE (PART NO. 82 00 168 855) 2 mm in diameter along the inner edge of the cap.
