Installing Intake-Air Distributor

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Intake-air distributor

1. 1.1  Replace seal on intake-air distributor.
2. 1.2  Position intake-air distributor -1-  and fit and tighten screws on intake-air distributor -2-  .
   • Tightening torque 9 Nm (6.5 ftlb.) 

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Electric line for generator

1. 2.1  Clip in clip -2-  on holder -3-  .

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Support for intake-air distributor

1. 3.1  Position support for intake-air distributor -1-  and fit and tighten screw -3-  .
   • Tightening torque 20 (15 ftlb) Nm 
2. 3.2  Screw on and tighten nut -2-  .
   • Tightening torque 10 Nm (7.5 ftlb.) 

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Intake camshaft hall sender

1. 4.1  Replace O-ring on hall sender for intake camshaft.
2. 4.2  Push on hall sender for intake camshaft -1-  and fit and tighten screw -3-  .
   • Tightening torque 9 Nm (6.6 ftlb.) 
3. 4.3  Connect and lock cable plug -2-  .

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High-pressure line

1. 5.1  Replace adapter on high-pressure pump -6-  and fuel distributor -7-  .
   1. 5.1.1  Coat the thread of the new  fuel distributor adapter with clean engine oil, screw it in and tighten it.
      • Tightening torque 40 Nm (30 ftlb.) 
   2. 5.1.2  Coat the thread or the new  high-pressure pump adapter with clean engine oil, screw it in and tighten it.
      • Tightening torque 40 Nm (30 ftlb.) 
2. 5.2  Coat the balls of the high-pressure line with clean engine oil and position them.
3. 5.3  Screw on union nuts -4 and 5-  .
4. 5.4  Position holding clamp -3-  and screw in screw -2-  .
5. 5.5  Tighten union nut on high-pressure pump -4-  .
   • Tightening torque 20 Nm (15 ftlb.) 
6. 5.6  Tighten union nut on fuel distributor -5-  .
   • Tightening torque 20 Nm (15 ftlb.) 
7. 5.7  Tighten screw -2-  .
   • Tightening torque 5 Nm (3.5 ftlb.) 

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Cable plug for knock sensor

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Lines on intake-air distributor

1. 7.1  Fit vacuum line -5-  .
2. 7.2  Position lines -1-  and clip them into clips -4-  . 7.3  Clip in clip -3-  .
3. 7.4  Remove stoppers.
4. 7.5  Connect and lock plug-in coupling -2-  .

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Cable plug

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Electric wire harness

1. 9.1  Position electric wire harness -1-  .
2. 9.2  Connect and lock cable plug -2-  .

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Electric wire harness for throttle housing

1. 10.1  Position electric wire harness for throttle housing -1-  .
2. 10.2  Clip in clips -3-  .
3. 10.3  Connect and lock cable plug -2-  .

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Pressure hose

1. 11.1  Connect pressure hose -1-  .
2. 11.2  Position and tighten screw-type clamp -2-  .
   • Tightening torque 5.5 Nm (4 ftlb.) 

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Cable plug

1. Fuel injectors for direct fuel injection (DFI)
2. Valve for intake-air distributor flap
3. Knock sensor
4. Wiring harness for fuel pressure sensor, potentiometer for intake-air distributor flap, coolant temperature sensor, hall sender

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Line

1. 13.1  Position coolant line -1-  .
2. 13.2  Screw in and tighten screws -2and 3-  .
   • Tightening torque 6 Nm (4.5 ftlb.)