WM 212419 Removing and installing intake manifold (includes eliminating leaks between intake manifold and turbocharger) Tools

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Technical values

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Preliminary work 1. Remove underbody panelling on the engine. -> 108019 Removing and installing engine guard (underbody panel) on DFI engines - section on "Removing" See: Service and Repair\Removal and
Replacement\108019 Removing and installing engine guard (underbody panelling)

2. Remove the air-cleaner element. -> 242419 Removing and installing air-cleaner element on DFI engines - section on "Removing" See: Air Filter Element\Service and Repair 3. Pull off the cable plug on the mass air flow sensor -1- .

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PCV and mass air flow sensor 4. Screw on a screw-type clamp between the mass air flow sensor (MAF sensor) and intake manifold. Remove MAF sensor. Removing intake manifold Information If you find leaks at the connection point between the intake manifold and turbocharger (drops of engine oil), the intake manifold and screw-type clamp must be replaced. 1. Remove the boost pressure pipe -1- . To do this, loosen both Henn couplings -2 and 4- . Once you have removed the boost pressure pipe, move the wire clip for the Henn coupling back into position. Loosen the spring band clamp -3- .

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Connection for bottom right pressure pipe to charge air cooler 2. Loosen the intake manifold clamp at the turbocharger -2- . Screw on a screw-type clamp. Use a side cutters or a suitable pliers to loosen a clamped one-way clamp (hose clamp). To do this, snip open the one-way clamp. The one-way clamp must not be reused.

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Intake manifold on turbocharger 3. Pull the intake manifold -1- off the turbocharger. 4. Disconnect the spring band clamp -2- from the intake manifold -1- and slide it onto the hose -3for the ambient air valve. Loosen the spring band clamp using universal assembly pliers Nr.723 if necessary.

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Ambient air valve at the right, above pressure pipe 5. Remove intake manifold. 6. If there is dirt or dust under the intake manifold, clean the affected components. Installing intake manifold Information If you find leaks at the connection point between the intake manifold and turbocharger (drops of engine oil), the intake manifold and screw-type clamp must be replaced. 1. If there is dirt or dust under the intake manifold, clean the affected components. 2. Fit the intake manifold on the turbocharger using a new screw-type clamp. 3. Complete the connections on the intake manifold and tighten the screw-type clamp to the specified tightening torque. -2- => Tightening torque: 7 Nm (5 ftlb.)

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Intake manifold on turbocharger Subsequent work 1. 2. 3. 4. Complete the intake system. Fit the mass air flow sensor (MAF sensor). Fit the air-cleaner element. Clean any oil stains off the underbody panelling.