Intake Manifold

Intake Manifold

Removing

CAUTION!
Follow the safety measures for releasing the high side fuel pressure. Refer to => [ High Side Fuel Pressure, Releasing ] Service and Repair.

• Observe the rules for cleanliness. Refer to => [ Clean Working Conditions ] Clean Working Conditions.

• If a fuel injector was pulled out of the cylinder head when removing the intake manifold, the Teflon seal must be replaced. Refer to => [ Fuel Injector Teflon Seal ] Fuel Injector Teflon Seal.

• Intake manifold overview. Refer to => [ Intake Manifold Overview ] Intake Manifold Overview.

- Remove the throttle valve control module (J338 ). Refer to => [ Throttle Valve Control Module ] Removal and Replacement.

- Disconnect all necessary electrical harness connectors.

- Disconnect the vacuum hose between the intake manifold and vacuum pump from the intake manifold.

CAUTION!
The fuel system is under pressure!

• Wear protective goggles and protective clothing to prevent injuries and contact with skin.

• Before disconnecting the connection, place a cloth around the connection point. Then release pressure by carefully disconnecting the connection.

- Disconnect the lines - 1, 2 and 3 -. To do so, press the release buttons.





Disconnect the vacuum lines - arrows - from the intake manifold and from cylinder head cover.





CAUTION!
Fuel system is under pressure!

• Wear protective goggles and protective clothing to prevent injuries and contact with skin.

• Before loosening line connections, place cloths around the connection point. Then release pressure by carefully pulling off the line.

Vehicles through 05.06





- Disconnect the fuel pipe - 4 - from the fitting - 3 -. Counter hold the fitting - 3 - while doing this.

- Counter hold the threaded support - 1 - and remove the banjo bolt - 2 -.

Vehicles from 06.06





- Open the hose clamp - 1 - and remove the fuel hose.

- Counter hold the fitting - 2 - and remove the fuel pipe - 3 -.

Continuation for All

- Disconnect the coolant pipe and oil dipstick guide from the intake manifold - arrows - and pull the oil dipstick guide upward out of the engine.





- Remove intake manifold support bolt and nut - arrows - and disconnect the connector - 1 - from the fuel pressure sensor (G247).





- Remove the intake manifold bolts.

- Carefully pull off the intake manifold with fuel rail from the cylinder head.

Installing

Installation is performed in the reverse order of removal, noting the following:

If a fuel injector was pulled out of the cylinder head when removing the intake manifold, replace the Teflon seal on he fuel injector. Refer to => [ Fuel Injector Teflon Seal ] Fuel Injector Teflon Seal.

Replace the O-rings between the fuel injector and fuel rail and lubricate them lightly with clean motor oil.

Position the intake manifold with fuel rail to the cylinder head and press evenly onto the fuel injectors.

If the intake flap motor (V157) or intake manifold was replaced, the intake manifold runner position sensor (G336) must be adapted to the Engine Control Module (ECM). Refer to "Guided Functions" in the vehicle diagnostic tester.