Removing and installing intake manifold

AR09.20-P-1310FA

Removing and installing intake manifold

10.5.95

 

Removing, installing

1

Remove air cleaner, install

AR09.10-P-1050F

2

Remove electronic accelerator actuator together with throttle valve body, install

AR30.20-P-1262FA

3

Remove cover of cable duct over intake manifold

4

Remove covers (20)

 Use screwdriver to release catch (ararow) for this step

5

Take off straps securing all the electric cables which run over the fuel rail

6

Remove ignition coils, install

AR15.12-P-2003FA

Detach vacuum lines of the components located at the intake manifold

 Pay attention to color coding of vacuum lines

Connection diagram of intake manifold

AR09.20-P-1310-01FA



Risk of explosion

Pay attention to accident prevention regulations!

7

Release fuel pressure through service valve at fuel rail

See Diagnosis Manual Engine, Volume 2, Index 3.2



*103589002100



*119589046300

8

Disconnect fuel feed line (17/3) and fuel return flow line (17/2)

 Collect fuel

9

Detach vacuum lines for brake unit at right and left sides of intake manifold

10

Unscrew bolts (14)

11

Remove air collecting box, install

Model 140

See Repair Instructions Automatic Heater Model 140, op. no. 83-140

12

Unscrew bolts (15)

 Tighten bolts from the middle to the outside. Pay attention to different bolt lengths.



*BA09.20-P-1001-01C

13

Unscrew bolt (19/10) at bracket (19/11)

14

Unclip power steering pump reservoir and push to the side

 Do not detach lines

17

Raise intake manifold (19) and take off to the side

 Use straightedge to inspect flange surfaces; process on dressing plate if necessary.

 When installing, ensure that no vacuum lines and electric cables are jammed in between

18

Remove intermediate flange (19/1)



*BA09.20-P-1002-01C

 Replace if necessary

 Replace shaped rubber seals (18/1)

19

Replace gaskets (18)

 Gaskets should engage in the locking sleeves (17)

19

Install in the reverse order

Number

Designation

Engine 120

BA09.20-P-1001-01C

Bolt of intake manifold to cylinder head

Nm

28

BA09.20-P-1002-01C

Bolt of intermediate flange to cylinder head

Nm

28