Replace intake manifold
Remove
4. |
Detach bulkhead closing part
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5. |
Remove brake force amplifier vacuum line
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6. |
Detach coolant expansion tank and set aside
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7. |
Detach charge air pipe (1) from throttle valve module (3)
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8. |
Detach charge air pipe (1)
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Detach hose clamp from transmission
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9. |
Remove throttle valve module (1)
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Disconnect wiring harness connector (2)
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• |
Unscrew bolt for wiring harness bracket (arrow)
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10. |
Remove dipstick guide tube
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11. |
Detach oil separator hose
• |
Detach vacuum hose, charge air control
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12. |
Remove 2x fuel line
• |
Seal fuel line connections with KM-6015
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13. |
Detach engine management wiring harness
• |
Disconnect 2x wiring harness connectors from engine control
unit (1)
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14. |
Disconnect wiring harness plug for mixture regulator oxygen
sensor
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15. |
Detach 2x wiring harness brackets from intake manifold
• |
Remove wiring harness connector and hose from differential
pressure sensor
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16. |
Disconnect wiring harness connector for charge pressure
sensor
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17. |
Raise vehicle by its full height
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18. |
Drain coolant
• |
Open drain bolt on radiator (1)
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19. |
Detach vacuum reservoir (1) with bracket (2)
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Set aside vacuum reservoir and bracket
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20. |
Detach wiring harness from alternator
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21. |
Lower vehicle by its full height
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22. |
Detach exhaust gas recirculation pipe (3)
• |
Unscrew 2x bolts (1) from flange of exhaust gas recirculation
valve
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• |
Unscrew 3x bolts (5) from intake manifold
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23. |
Detach exhaust gas recirculation valve (2)
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Detach coolant hose from heater core
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• |
Remove 2x wiring harness plug
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• |
Remove vacuum hose
Note: Set aside exhaust
gas recirculation valve. The exhaust gas recirculation valve cannot
be removed.
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24. |
Raise vehicle by its full height
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26. |
Lower vehicle by its full height
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27. |
Detach oil separator hose from timing case
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28. |
Detach intake manifold (1)
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Unscrew 9x bolts (2, 3)
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29. |
Detach throttle valve connector adapter
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30. |
Detach charge pressure sensor
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Install
31. |
Detach charge pressure sensor
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32. |
Attach throttle valve connector adapter
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33. |
Install intake manifold
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34. |
Connect wiring harness connector for charge pressure sensor
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35. |
Attach oil separator to cylinder head
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36. |
Attach exhaust gas recirculation valve
• |
Attach coolant hose to heater core
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• |
Push on 2x wiring harness plug
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37. |
Attach exhaust gas recirculation pipe
• |
Tighten 2x bolts on flange of exhaust gas recirculation valve
9 Nm
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• |
Tighten 3x bolts on intake manifold 9
Nm
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38. |
Install throttle valve module
• |
Tighten bolt, wiring harness bracket
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• |
Connect wiring harness plug
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39. |
Attach oil separator hose to timing case
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40. |
Attach 2x wiring harness brackets to intake manifold
• |
Connect wiring harness connector and hose from differential
pressure sensor
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41. |
Raise vehicle by its full height
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42. |
Attach wiring harness to alternator
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43. |
Insert dipstick guide tube
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44. |
Attach vacuum reservoir bracket
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45. |
Attach vacuum reservoir to vacuum reservoir bracket
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46. |
Lower vehicle by its full height
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47. |
Fasten oil dipstick guide tube
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48. |
Fit charge air pipe at throttle valve module
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49. |
Fasten charge air pipe
• |
Attach hose clamp to transmission
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51. |
Connect wiring harness connector for mixture regulation oxygen
sensor
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52. |
Connect vacuum line for brake force amplifier
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53. |
Install battery holder
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54. |
Attach coolant expansion tank
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55. |
Install bulkhead closing part
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56. |
Connect battery
• |
Attach earth clamp to earth terminal
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57. |
Fill and bleed cooling system
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59. |
Program volatile memories
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