Table of contents: Removal ↓ Installation ↓
Intake manifold parts and components 1. Intake manifold. Electric motor for changing the geometry of the intake manifold "V183" with the sensor of the position of the flaps of changing the geometry of the intake manifold "G513" (single node), do not disassemble; 2. Bolt, 8 Nm; 3. Gasket, replacement; 4. Sealing ring, replacement; 5. Connecting pipe to the EGR radiator; 6. Bolt, 20 Nm; 7. Gasket, replacement 8/10/11. Bolt, 10 Nm; 9. Electric motor for driving the air flap/intake flaps "V157", with air flap potentiometer "G69"; 12. Oil dipstick; 13. EGR valve "N18", with EGR potentiometer "G212"
Removal
Remove the engine cover. Remove the soundproofing cover from the valve cover. Remove connectors "5, 6, 7 and 8" from the glow plugs as follows. When disconnecting the glow plug connectors, do not damage the electrical connections, otherwise the entire wiring harness will need to be replaced. Do not squeeze the pliers "3314" too hard to disconnect the connectors, otherwise the support sleeve may be damaged.
Use pliers "3314" with groove "arrow A" to grasp the edge of the support sleeve "arrow B" and disconnect the connectors from the glow plugs.
Remove the high-pressure fuel line "4" for this, unscrew the union nuts of the high-pressure fuel pump "1" and the fuel rail "5". Unscrew the fastening screws of the high-pressure fuel line "arrow". Remove the wiring harness "6" from the fasteners.
Disconnect fuel lines "2" and "3" from the high-pressure fuel pump. Unscrew the "arrow" screws of the fuel line brackets. Avoid kinking the fuel lines. Follow the rules for maintaining cleanliness when working with the injection system. Immediately close open connectors with suitable plugs. Disconnect the following electrical connectors.
- 1. Fuel pressure sensor "G247"
- 2. Fuel pressure regulator "N₂76"
- 3. Electric motor for changing the geometry of the intake manifold "V183"
- 4. Electric motor for driving the air damper/intake flaps "V157"
- 5. EGR valve "N18"
Loosen the clamp "arrow" of the air hose and disconnect it from the air damper drive motor "V157" by moving it downwards. Unscrew the screw securing the oil dipstick bracket. Remove the connecting pipe of the EGR system from the EGR valve "N18". Unscrew the bolts securing the intake manifold from the outside inwards and crosswise. Remove the intake manifold.
Installation
Installation is in reverse order, and the following must be done: Replace the gaskets. Tighten the intake manifold mounting bolts from the outside inward and crosswise.