Removing Intake-Air Distributor, Side 4-6

Information 

Specifications for wrench sizes (a/f specifications) for screw heads are described as follows:

• Torx screws: (E..) for external Torx, (T..) for internal Torx. 
• Hexagon-head bolts (internal and external hexagon): Wrench size (a/f) 

1. Remove holder for oil filler neck.
   1. 1.1. Open the holder at the top -1-  by unclipping the locking mechanism.
      Fig 1: Identifying Latch On Oil Filler Neck Holder (Top)

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   2. 1.2. Unscrew one internal Torx screw (T27, M6 x 12) -1-  at the top of the intake-air distributor.
      Fig 2: Identifying Filler Neck Holder Fastening Screw (Top)

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   3. 1.3. Unscrew the second internal Torx screw (T27, M6 x 12) -1-  between the intake air line and bottom of intake-air distributor.
      Fig 3: Identifying Filler Neck Holder Fastening Screw (Bottom)

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2. On vehicles with air conditioning, disconnect air-conditioning compressor and accessories. 
   1. 2.1. Loosen fuel line -2-  at the fastening point -1-  .
      Fig 4: Identifying Fuel Line

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   2. 2.2. Disconnect the fuel lines -4-  on the fuel cooler. Counter at the fuel cooler (a/f 14) when loosening the union nuts.
      Fig 5: Disconnecting Fuel Lines On Fuel Cooler

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   3. 2.3. Pull engine compartment temperature sensor -1-  out of the rubber holder.
      Fig 6: Pulling Engine Compartment Temperature Sensor

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   4. 2.4. Disconnect the compressor. Unscrew three M8 screws -5-  to do this.
   5. 2.5. Carefully lift off the compressor and place it to one side together with the refrigerant lines (use protective surface). Secure with a tie-wrap to prevent them from slipping, if necessary.
3. Disconnect and expose the engine wire harness at the transfer point.
   1. 3.1. Cut tie-wrap -arrow-  .
      Fig 7: Locating Engine Wire Harness

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   2. 3.2. Open round connectors on engine wire harness.

      To do this, turn bayonet lock anticlockwise and pull off.

      Fig 8: Identifying Engine Wire Harness Round Connectors

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   3. 3.3. Unplug cable plug for ignition coil on cylinder 4 -1-  .

      Pull cable plug -2-  off the camshaft sensor.

      Fig 9: Pulling Cable Rail And Cable Plug, Side 4-6

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   4. 3.4. Pull cable rail up off the fuel collection pipe -arrow-  .
4. Disconnect fuel collection pipe with fuel injectors 4-6.
   1. 4.1. Loosen both fuel lines (a/f 17) -1 and 2-  and make sure to counter when doing this (a/f 19).
      Fig 10: Identifying Fuel Collection Pipe And Fuel Lines (Side 4-6)

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   2. 4.2. Unscrew two external Torx screws (M6 x 12) -13-  .
   3. 4.3. Pull fuel collection pipe -2-  with fuel injectors 4-6 off the intake-air distributor.
   4. 4.4. Disconnect cable plug for fuel injectors 4-6.
   5. 4.5. Move the fuel collection pipe -2-  as far as possible to the side.
      Fig 11: Identifying Fuel Collection Pipe And Fuel Injectors (Side 4-6)

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5. Remove intake-air distributor, side 4-6.

   Use a 5-mm socket-wrench insert with a ball joint to loosen hidden screws and a bar magnet to pull them out. 

   1. 5.1. Unscrew six hexagon socket head bolts (a/f 5, M6 x 25) and remove the intake-air distributor.
   2. 5.2. Lift up the intake-air distributor -1-  and turn it slightly until it is free, then remove it over the hydraulic pump.
   3. 5.3. Replace molded seals.
      Fig 12: Turning Right Intake-Air Distributor

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6. Clean fuel injectors in an ultrasound bath.
   1. 6.1. To do this, remove spring clamps and pull the fuel injectors out of the fuel collection pipe one at a time.
   2. 6.2. Before cleaning the fuel injectors, mark them with a water-resistant marker to facilitate re-installation.
7. Replace O-rings on the fuel injectors.