Intake Manifold Gasket, Replace
Remove
Important: In vehicles as of
model year 04 with ESP - every time the battery is disconnected,
the steering angle sensor loses its basic setting and must be
recalibrated
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2. |
Disconnect battery
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3. |
Remove air cleaner housing
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4. |
Remove charge air pipe to turbocharger (1)
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Unscrew 2x bolt (arrows)
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5. |
Remove oil dipstick guide tube (1)
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6. |
Disconnect MAP sensor wiring harness plug
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Release wiring harness plug in direction of arrow
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7. |
Release engine vent hose
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8. |
Remove fuel filter housing (2)
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Disconnect 4 lines (1) and (4)
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Disconnect 2 wiring harness plugs
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9. |
Loosen coolant compensation tank
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Unclip coolant compensation tank
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11. |
Remove charge air pipe at intake manifold (1)
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Unscrew 4 bolts (arrows)
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12. |
Drain coolant
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Place collecting basin underneath.
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13. |
Detach 2 heating hoses
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Open 2 quick-release fittings
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14. |
Loosen upper EGR valve
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Loosen EGR valve metal pipe
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16. |
Remove lower engine compartment cover / splash protection
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17. |
Loosen oil separator (3)
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Unscrew 2x bolt (arrows)
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18. |
Loosen lower EGR valve
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21. |
Remove intake manifold (1)
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23. |
Install intake manifold
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Tighten 9 bolts 25 Nm
Note: Note differing
bolt lengths (2).
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Install
24. |
Attach EGR valve
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Attach EGR valve metal pipe
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26. |
Attach lower EGR valve
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28. |
Install lower engine compartment cover / splash protection
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30. |
Fit charge air pipe to intake manifold
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31. |
Attach 2x heater hose
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Attach 2 quick-release fittings
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33. |
Install fuel filter housing
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Connect 2 wiring harness plugs
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34. |
Fasten coolant compensation tank
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Clip in coolant compensation tank
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35. |
Attach engine vent hose
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36. |
Connect MAP sensor wiring harness plug
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Lock wiring harness plug
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37. |
Install oil dipstick guide tube
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38. |
Install charge air pipe at turbocharger
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39. |
Install air cleaner housing
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42. |
Program volatile memory
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