Remove/install intake manifold

AR09.20-D-1310E

Remove/install intake manifold

15.11.2019

Engine

111.984 in model 901.6, 902.6, 903.6, 904.6

*

1

Air intake hose

2

Clamp

3

Injection valve connector

4

Air pump switchover valve

5

Purge control valve

6

Vacuum line

7

Fuel line

8

Air pump

9

Intake manifold

10

Idle speed control actuator

11

Intake manifold gasket

12

Cylinder head cover trim panel

 

Remove/install

1

Disconnect battery ground line

2

Remove air intake hose (1)

AR09.10-D-8030F

3

Remove idle speed control actuator (10)

AR30.22-D-1152B

4

Remove air pump switchover valve (4)

AR14.30-D-7255A

5

Remove purging switchover valve (5)

AR47.30-D-8220A

6

Unclip clip (2) at cylinder head cover and remove connectors (3) from injection valves at intake manifold

7

Remove trim panel for cylinder head cover (12)

AR01.20-D-5014-02C

 Bolt, trim panel of cylinder head cover to cylinder head cover

*BA01.20-N-1002-01A

 Danger

Risk of death when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC)

Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines.

AS00.00-Z-0035-01A

8

Unplug the connector from the primary side of ignition coils, and run the lines out of the housing of the cylinder head cover

 The lines are routed together with other lines in a wiring harness through the intake manifold downwards.

9

Remove vacuum lines (6) at intake manifold

AR09.20-D-1310-06B

 Vacuum line at intake manifold vacuum fitting

*BA09.20-N-1004-02A

10

Remove air pump (8) from the bracket

 Do not disconnect lines of air pump.

 Danger

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contactwith fuel.

No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only.
Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

11

Detach fuel lines (7) at engine

AR47.25-D-1000-01D

12

Remove intake manifold (9) from cylinder head

AR09.20-D-1310-07E

 Intake manifold to cylinder head

*BA09.20-N-1001-02A

13

Install in the reverse order

 Crankcase ventilation, cylinder head cover

Number

Designation

Engine 111.948/978/979/984

BA01.20-N-1002-01A

Bolt, trim panel of cylinder head cover to cylinder head cover

Nm

9

 Intake manifold, intake manifold preheating

Number

Designation

Engine 111.979/984

BA09.20-N-1001-02A

Intake manifold to cylinder head

M8

Nm

21

 Intake manifold, intake manifold preheating

Number

Designation

Engine 111.979/984

BA09.20-N-1004-02A

Vacuum line at intake manifold vacuum fitting

Nm

30