Two Piece Intake Manifold: Overview
Two Piece Intake Manifold
=> [ Intake Manifold Overview ]
=> [ Fuel Rail, Injectors and High Pressure Pump Overview ]
=> [ Air Filter Housing Overview ]
Intake Manifold Overview
1 Bolt
• 10 Nm
2 Upper Intake Manifold
• Removing and installing, refer to => [ Upper Intake Manifold ] Two Piece Intake Manifold.
3 Grommet
• Replace if damaged.
4 to Brake Booster
5 Bolt
• 10 Nm
6 from Evaporative Emission (EVAP) Canister Purge Regulator Valve (N80)
7 Bolt
• 20 Nm
8 Rear Intake Manifold Support
9 Seal
• Replace
10 Bolt
• 7 Nm
11 Throttle Valve Control Module (J338)
• With the throttle drive (for Electronic Power Control (EPC)) (G186), throttle drive angle sensor 1 (for EPC) (G187) and throttle drive angle sensor 2 (for EPC) (G188).
• When replacing, adapt the Engine Control Module (ECM) to the throttle valve control module, refer to "Guided Functions" in the vehicle diagnostic tester.
12 Bolt
• 3.5 Nm
13 Connection
• For the crankcase ventilation.
• With the Positive Crankcase Ventilation (PCV) heating element (N79).
• From the cylinder head cover.
14 Front Intake Manifold Support
15 Gasket
• Replace if damaged.
• Lightly lubricate with engine oil before installing and insert it into the upper intake manifold.
16 Gasket
• Replace
• Make sure it fits securely inside the lower intake manifold.
17 Lower Intake Manifold
• Removing and installing, refer to => [ Lower Intake Manifold, with Fuel Rail ] Two Piece Intake Manifold.
18 Fuel Rail
• For cylinders 2, 4 and 6.
• Fuel injector springs - item 23 - must be replaced before installing.
• Tighten uniformly, starting from the inside and working toward the outside.
• Fuel rail, injectors and high pressure pump overview. Refer to => [ Fuel Rail, Injectors and High Pressure Pump Overview ].
19 Bolt
• 30 Nm + 90° (1/4) additional turn.
• Replace
• Tighten the fuel rail uniformly, starting from the inside and working toward the outside.
20 Bolt
• 8 Nm
Fuel Rail, Injectors and High Pressure Pump Overview
• Do not disassemble the high pressure pump!
• If a fuel injector is removed, the combustion chamber Teflon seal and O-ring must be replaced. Refer to => [ Fuel Injector Teflon Seal and Washer ] Two Piece Intake Manifold.
• Observe the rules for cleanliness. Refer to => [ Clean Working Conditions ] Multiport Fuel Injection.
CAUTION!
Read the safety precautions before beginning work. Refer to => [ Safety Precautions ] Fuel Supply.
The fuel pressure in the high pressure pipe can be up to 120 bar! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before disconnecting the fuel pipe, place a cloth around the connection point. Then release pressure by carefully loosening the union nuts.
1 Bolt
• 30 Nm + 90° (1/4) additional turn.
• Replace
• Tighten the fuel rail uniformly, starting from the inside and working toward the outside.
2 Fuel Rail
• For cylinders 1, 3 and 5.
• Always replace the fuel injector springs - items 11 and 23 - before installing.
• Tighten uniformly, starting from the inside and working toward the outside.
3 Spring Type Clip
4 Low Fuel Pressure Sensor (G410)
• 15 Nm
5 Fuel Supply Line
• From the fuel tank.
• With a mount for the low fuel pressure sensor (G410).
• Always replace the fuel hose because it is damaged when it is removed from the ridged connections.
6 Bolt
• 8 Nm
7 Bolt
• 8 Nm
8 Bracket
• For the fuel supply pipe.
9 O-ring
• Replace
• Before installing, lubricate with clean engine oil.
10 Support Washer
• Replace if damaged. Refer to => [ Fuel Injector Teflon Seal and Washer ] Two Piece Intake Manifold.
11 Spring
• Replace for every removal of the fuel rail.
• Ensure the spring is securely seated.
12 Cylinder 1 Fuel Injector (N30)
• Cylinder 3 fuel injector (N32).
• Cylinder 5 fuel injector (N83).
• Removing and installing, refer to => [ Fuel Injectors ] Two Piece Intake Manifold.
• The long fuel injectors for cylinders 1, 3 and 5 must not be separated.
13 Seal
• Replace
• Before installing, lubricate with clean engine oil.
14 Low Pressure Fuel Hose
• Between the high pressure pump and fuel rail.
• Always replace the fuel hose because it is damaged when it is removed from the ridged connections.
15 Spring Clamps
16 High Pressure Fuel Line
• 28 Nm
• Fuel pressure in the high pressure line can be up to 120 bar! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before disconnecting the fuel pipe, place a cloth around the connection point. Then release pressure by carefully loosening the union nuts.
• To loosen and tighten the union nut, counter hold on the connection of the high pressure pump using a wrench.
• Before installing: tighten the connections on the high pressure pump to 40 Nm.
• Do not install when under tension.
• To install, first tighten the union nuts by hand.
17 Connecting Line
• 28 Nm
• Do not install when under tension.
• To install, first tighten the union nuts by hand.
18 Pump Plunger
• Lubricate the O-rings with clean engine oil before installing.
19 O-ring
• Replace
• Before installing, lubricate with clean engine oil.
20 High Pressure Pump
• With the fuel pressure regulator valve (N276).
• To loosen and tighten the fuel line, counter hold on the connection using a wrench.
• Removing and installing, refer to => [ High Pressure Pump ] Two Piece Intake Manifold.
• Before installing the fuel line, first tighten the connection for the fuel lines:
High pressure line connection: 40 Nm.
21 Bolt
• 10 Nm
22 Cylinder 2 Fuel Injector (N31)
• Cylinder 4 fuel injector (N33).
• Cylinder 6 fuel injector (N84).
• Removing and installing, refer to => [ Fuel Injectors ] Two Piece Intake Manifold.
23 Spring
• Replace for every removal of the fuel rail.
• Ensure the spring is securely seated.
24 Support Washer
• Replace if damaged. Refer to => [ Fuel Injector Teflon Seal and Washer ] Two Piece Intake Manifold.
25 O-ring
• Replace
• Before installing, lubricate with clean engine oil.
26 Fuel Rail
• For cylinders 2, 4 and 6.
• Fuel injector springs - item 23 - must be replaced before installing.
• Tighten uniformly, starting from the inside and working toward the outside.
• Removing and installing, refer to => [ Lower Intake Manifold, with Fuel Rail ] Two Piece Intake Manifold.
27 Bolt
• 30 Nm + 90° (1/4) additional turn.
• Replace
• Tighten the fuel rail uniformly, starting from the inside and working toward the outside.
28 Fuel Pressure Sensor (G247)
• 22 Nm
• Before assembly, lubricate the front sealing point and threads with clean motor oil.
29 Cap
• 22 Nm
30 Pressure Relief Valve
• Lightly lubricate the O-rings with clean engine oil before installing.
• Replace the removed valve.
• Press in by hand using a 8 mm hex wrench.
31 O-ring
• Replace
• Before installing, lubricate with clean engine oil.
Air Filter Housing Overview
1 Regulator Flap
• Only on cold climate vehicles.
• With a thermal element.
• Intake air pre-heating, checking. Refer to => [ Intake Air Pre-Heating, Checking ] Two Piece Intake Manifold.
2 Bolt
• 2 Nm
3 Does Not Apply
4 Connecting Hose
• To the throttle valve control module (J338).
5 Filter Element
6 Mass Airflow (MAF) Sensor (G70)
7 Seal
• Replace if damaged.
8 Upper Air Filter Housing
9 Bolt
• 2 Nm
10 Connection
• Clipped into the upper air filter housing.
11 Nut
• 8 Nm
12 Cover
13 Air Duct
• Fastened to the lock carrier.
14 Bolt
• 5 Nm
15 Gasket
• Replace if damaged.
16 Rubber Bushing
17 Bolt
• 10 Nm
18 Bracket
• For the air filter housing.
19 Mounting Pin
• 9 Nm
20 Connection
• Not installed on all vehicles.
• For the warm air intake.
21 Lower Air Filter Housing