Removing Intake-Air Distributor

→ Ventilate the work area well.

→ Never ingest or inhale.

→ Read specific information on the Hazard Sheet.

→ Wear personal protective gear.

→ Do not smoke, eat or drink in the work area.

→ Avoid contact with hot parts or sources of ignition.

→ Use suction to remove ignitable vapours.

→ Attach warning sign in a clearly visible position.

→ Thoroughly clean connection points and adjacent areas before loosening them. If the engine is very dirty, wash it before starting disassembly work.

→ Lay removed parts on a clean surface and cover them. Do not use fibre-shedding cloths.

→ Carefully cover components or seal them if repair work will not be carried out immediately. Place rubber caps on connections. Seal intake openings with film or adhesive tape.

→ Only install clean parts. Do not take spare parts out of the packaging until just before installation.

→ Never use compressed air when the system is open. Do not move the vehicle.

→ Perform leak test.

Information 

• Do not bend high-pressure lines. Always remove the high-pressure distributor pipe and other fuel-supply components in the high-pressure area completely. Check that the connection points are not damaged and are perfectly clean and make sure there is no thread damage. Fit union nuts on all connection points by hand before screwing in screws or bolts. Remove dirt on the conical/ball joints. Check connection points for leaks following fitting. 

Information 

• The ignition must be switched off when working on the fuel system. 
• Absorb any escaping fuel using a suitable binding material or a cloth. 
• Cloths which have absorbed fuel must be disposed of according to the applicable national laws. 
• The fuel system must be depressurised before starting work on it. 
• Only work on the fuel system in well-ventilated rooms. 
• Any seals which have been removed must always be replaced. 

1. Remove connections and accessories on intake-air distributor.
   Fig 1: Identifying Intake-Air Distributor Connections

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   1. 1.1. Screw off oil filler cover. -1- 
   2. 1.2. Remove eyelet. Loosen two screws. -2- 
   3. 1.3. Disconnect throttle valve and expose cable. -3- 
   4. 1.4. Loosen tank ventilation line and release it from the intake-air distributor. -6- 
   5. 1.5. Loosen positive crankcase ventilation line and release it from the intake-air distributor. -5- 
   6. 1.6. Disconnect crankcase heater. -4- 
2. Remove upper screw on sheetmetal holder. -Top arrow- 
   Fig 2: Locating Sheetmetal Holder Mounting Screw

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3. Pull vacuum line out of the intake-air distributor. Use a screwdriver to prise it off if necessary. -arrow- 
   Fig 3: Locating Vacuum Line

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4. Expose throttle housing cable -1-  . Remove screw on intake-air distributor. -2- 
   Fig 4: Identifying Throttle Valve

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5. Remove rear screw on intake-air distributor. -1- 
   Fig 5: Locating Intake-Air Distributor Mounting Screw

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6. Press the two coolant hoses aside and remove screw on oil dipstick. Pull out oil dipstick. -1- 
   Fig 6: Pressing Coolant Hoses

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7. Pull off vacuum line on vacuum unit for intake-air distributor -1-  . Unclip changeover valve, disconnect it and set it aside. -2 and 3- 
   Fig 7: Identifying Vacuum Lines

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8. Loosen water tube. To do this, remove the screw on the intake-air distributor -1-  and press the water tube forward -arrow-  . Take the water tube out of the notches and press it down -arrow-  .
   Fig 8: Removing Water Tube

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9. Disconnect cable plug for high-pressure sensor. Remove high-pressure pump. → Removing High-Pressure Pump 
10. Remove high-pressure line between the fuel distributor pipes. To do this, loosen the union nuts and remove line. -1 and 2-  See Fig 9-21-  .
    Fig 9: Identifying High-Pressure System Threaded Connections

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    Fig 10: Identifying DFI Injection System (3.6L)

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11. Loosen three screws on the intake-air distributor at the sides in the centre of the intake-air distributor. Use a thin Torx socket (e.g. Klann KL-4041-240) to do this. These three screws are integrated in the intake-air distributor so that they cannot be lost.
    Fig 11: Identifying Intake-Air Distributor Mounting Screws

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12. Remove one front screw at the side of the intake-air distributor.
    Fig 12: Identifying Intake-Air Distributor Side Screws

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    Information 

    • The lower fuel distribution pipe also secures the intake-air distributor. 
    • Always open the fuel high-pressure system when removing the intake-air distributor. 
    • The intake-air distributor sits under the fuel distribution pipe for cylinders 2, 4 and 6 
13. Loosen lower fuel distributor pipe (for cylinders 2, 4 and 6). To do this, insert a suitable extension in between the water tube and remove the three screws using a multiple-tooth socket. see → -19-  .
    Fig 13: Identifying Lower Fuel Distributor Pipe Accessing Screws

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14. Lift off the intake-air distributor complete with the lower fuel distributor pipe. To do this, first raise the intake-air distributor on the exhaust side and tilt it -1-  , then lift it off the cylinder head on the intake side. -2- 
    Fig 14: Removing Intake-Air Distributor

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