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Removing, installing |
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| 1 |
Remove air cleaner, install |
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AR09.10-P-1050E |
| 2 |
Partially drain coolant |
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| 3 |
Unplug al the plug connections of the cables which run across the intake manifold or of the electrical components at the intake manifold |
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| 4 |
Unclip guide rail for ignition cables |
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| 5 |
Detach vacuum lines of the components located at the intake manifold |
Pay attention to color coding of vacuum hoses |
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Connection diagram of intake manifold |
AR09.20-P-1310-01E |
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Risk of explosion |
Pay attention to accident prevention regulations! |
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| 6 |
Release fuel pressure through service valve at the fuel rail |
See Diagnosis Manual Engine, Volume 2, Index 3.1 |
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Fig 2 |
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Figure |
| 7 |
Unbolt fuel feed line (17/3) and return flow line (17/2) |
Collect fuel |
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| 8 |
Disconnect vacuum line for brake unit |
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Fig 4 |
| 9 |
Remove guide piece (27) |
Removal
: pull plastic nipple out of guide piece.
Do not damage guide piece.
Installation
: ensure that the plastic nipple engages properly in the guide piece. |
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| 10 |
Detach bowden cable (30) at throttle control lever (9) |
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| 11 |
Pull bowden cable (30) out of fix lever (10) |
Removal
: press together plastic clip (28) |
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| 12.1 |
Detach control pressure bowden cable (98) |
AT |
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| 13 |
Separate plug connection of electronic accelerator actuator (M16/1x1) and detach cable |
Ensure the electric cable of the electronic accelerator actuator is correctly routed: ↓ |
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Model 124.036 up to 06/93 |
AR30.20-P-1262-01A |
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Model 124.034 |
AR30.20-P-1262-01B |
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Model 124.036 as of 07/93 |
BT30.20-P-0001-01A |
| 14 |
Disconnect coolant hose (33) at front of intake manifold |
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| 15 |
Disconnect coolant hose at rear of intake manifold |
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| 16 |
Unscrew bolts (14, 15, 16) |
Pay attention to different lengths of bolts and different spacers (13). Oil bolt threads with assembly oil. Tighten bolts according to tightening diagram: ↓ |
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Tightening diagram of intake manifold attachment |
AR09.20-P-1310-03E |
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*BA09.20-P-1001-01C |
| 17 |
Take off intake manifold (19) |
When installing, ensure that no vacuum lines and electric cables are jammed in between and that the intake manifold engages in the dowel pins. |
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| 18 |
Use straightedge to inspect flange surfaces |
If necessary, process on dressing plate, or: ↓ |
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replace intake manifold |
AR09.20-P-1310-04E |
| 19 |
Replace gaskets (18) |
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| 20 |
Install in the reverse order |
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| 21 |
Adjust throttle control |
With ASR code 471a |
AR30.10-P-1010EA |
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Without ASR code 471a |
AR30.10-P-1010EB |
| 22 |
Inspect idle speed, set |
See Diagnosis Manual Engine Volume 1 |
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