Table of contents: Intake manifold (CDNB, CDNC, SAEV,… ↓ Fuel rail ↓ Removal and installation the intake… ↓ Removal and installation the fuel… ↓
Intake manifold (CDNB, CDNC, SAEV, CDZA, SAEA, CADA)
1. Intake air temperature sensor bolt "G42": 9 Nm.
2. Intake air temperature sensor "G42".
3. Electromagnetic valve 1 of the activated carbon absorber "N80": with double check valve.
4. Intake manifold: tighten to a torque of 9 Nm.
5. Vacuum reservoir for charge air regulating flaps (intake manifold regulating flaps).
6. Intake manifold flap valve "N316".
7. Injectors: replace the seal. and Teflon rings, take into account the installation. position.
8. Intake manifold support.
9. Intake manifold pipe bolt: 23 Nm.
10. Fastening nut for intake manifold pipe: 10 Nm.
11. Throttle body bolts "J338": 10 Nm.
12. Throttle valve control unit "J338", throttle valve drive "G186", throttle valve drive angle sensor 1 "G187" and throttle valve drive angle sensor 2 "G188"; after replacing the throttle control module "J338", it must be re-aligned with the engine control unit "J623", use the Tester for this.
13. Lip seal: replace.
Fuel rail
1. Nozzle; always replace together with the combustion chamber seal (Teflon seal. ring); replace the seal. rings, take into account installation. position.
2. Support ring.
3. Fuel rail.
4. High pressure pump: with fuel pressure regulating valve "N276"; there is an electric heater in the fuel tank. fuel pump, which supplies fuel to the mechanics. high pressure pump: when installing a high pressure pump, it is necessary to ensure that the fuel. no dirt got into the system; before installing the high pressure fuel pump. the system should not be under pressure, relieve the pressure; install fuel lines without distortions.
5. Roller pusher.
6. Fuel pressure regulator "N276".
7. High pressure pump bolts: tighten crosswise to 5 Nm and then tighten to 20 Nm.
8. Fuel supply nipple. highways to fuel. ramp: replace, 40 Nm.
9. Fuel supply union nut. highway: 20 Nm.
10. Compression valves (intake manifold flaps).
11. Gasket: replace.
12. Intake manifold.
13. Vacuum reservoir for charge air regulating flaps.
14. Throttle control unit "J338", throttle actuator "G186", throttle actuator angle sensor 1 "G187" and throttle actuator angle sensor 2 "G188": after removing and installing, or replacing the throttle control unit "J338", it is necessary to re-adapt it to the engine control unit "J623", use the tester for this; 7 Nm.
15. Intake manifold bolts: 9 Nm.
16. Intake manifold flap potentiometer "G336": after each removal and installation or replacement of the intake manifold flap potentiometer "G336" or the intake manifold, it is necessary to adapt the intake manifold flap potentiometer "G336" to the engine control unit "J623"; to do this, use the Tester in the "Guided Functions" mode.
17. Fuel pressure sensor "G247": 27 Nm; lubricate the threads with clean oil; always replace the nipple and tighten to 40 Nm.
Removal and installation the intake manifold
When removing or replacing fuel. to re-adapt the intake manifold valve potentiometer "G336" to the engine control unit "J623," use a tester. To access the injectors, remove the intake manifold and fuel rail. rail. Be sure to replace the combustion chamber seal (Teflon) and the sealing ring. The fuel in the fuel system is under pressure! Disconnect the (-) terminal from the battery. Remove the engine cover. Disconnect the vacuum line "arrow" to the activated carbon absorber. Disconnect the following connectors.
1. Electromagnetic valve 1 of the activated carbon absorber "N80"; 2. Knock sensor 1 "G61"; 3. From the intake manifold flap valve "N316", fuel pressure sensor "G247" and Hall sensor "G40"; 4. From the injectors; 5. Throttle control unit "J338"; 6. Intake air temperature sensor "G42".
Disconnect connector "1" from Hall sensor "G40".
Open the clamp "arrow" of the air duct hose and disconnect the hose from the throttle valve module "J338" downwards.
Disconnect the vacuum line "1" at the disconnect point "2". Disconnect the system hose. crankcase ventilation "3".
Open the spring clamp -upper arrow- and pull off the fuel supply hose. hose with fuel injection pump. Open the fuel union nut. high-pressure lines - lower arrow - on the fuel injection pump. The fuel system should not be under pressure. Place a clean rag under the leaking fuel. Close open fittings with clean plugs, making sure that no contaminants get into the fuel. syst..
Remove the vacuum line "arrow" from the intake manifold throttle valve "N316".
Unscrew the bolt "arrow" of the coolant line from the intake manifold.
Disconnect the electrical connector from the fuel pressure sensor "G247" "1".
Slightly loosen the fastening nut "1" and completely unscrew the bolt "2".
Disconnect the oil filter using the Hazel tension band "2171-1" or the oil filter wrench "3417" and remove the oil filter. Unscrew the bolts from the intake manifold using the T10347 wrench. To remove inaccessible bolts without the "T10347" socket, remove the "J338" throttle control module. Carefully lift the intake manifold off the fuel tank. ramp with cylinder head.
Disconnect connector "1" of the intake manifold throttle valve potentiometer "G336" and remove the intake manifold. The injectors may remain in the fuel. ramp. Cover the intake ports with a clean rag. Separate the intake manifold from the fuel. ramps.
Install
Ensure that the injectors are installed correctly. Place the intake manifold through the mounting pins (left and right below) onto the cylinder head. Installation is in reverse order.
Removal and installation the fuel distributor
When removing or replacing fuel. the intake manifold valve potentiometer "G336" must be re-adapted to the engine control unit "J623". The intake manifold must be removed. Remove clamp "1". Remove the activated carbon absorber hoses. Disconnect the fuel line from the fuel tank. fuel rail. Unscrew both "arrow" bolts from the fuel rail. Remove the fuel rail from the intake manifold.
Install
Always replace both fuel supply line fittings. Secure the fuel. highway. Connect the connector. Install the intake manifold. Installation in reverse order.