Attention! Risk of injury from fuel jet. To release fuel pressure before opening the fuel system, wrap the connection with a clean rag and carefully loosen the connection. Dirt can cause problems.
Disconnect fuel pressure line -1- and line to canister -2-.
Unlock catch -arrow- and detach vacuum hose -1-. Detach vacuum hose from mounts on air duct -2-. Release the air hoses from the mountings on the charge air pipe.
Disconnect connector -1-. -Arrows- ignore.
Unlock catches -arrows- with puller -T10527- and remove air duct.
Disconnect connectors.
1. Canister solenoid valve 1 -N80-
3. Throttle valve unit -J338-
4. Intake manifold pressure sender -G71 -
Remove screw -arrow-. Press release buttons and disconnect canister hose -2-. Unclip fuel line -5- and coolant line -6- from retainers on intake manifold and move to one side. Remove connector -2- for low oil pressure sender -F378- -1-.
Remove screw -1- and pinch coolant hose with hose clamps up to 25 mm -MP7-602 (3094) -. Loosen clamps -arrows- and detach coolant hoses.
Detach wiring harness -1-, coolant hose -3- and crankcase breather hose -2- from intake manifold. Remove screws -arrows*.
Position -1- do not touch.
Pull the intercooler -1- out of the intake manifold towards the front and at the same time in the direction of -arrow-. Move the intercooler aside. Remove screws -arrows-.
Position -1- do not touch. Remove intake manifold -2-.
Installation in reverse order.
Intake manifold torque and tightening sequence
Tighten the screws in stages as follows.
Note: Replace gaskets and O-rings.
Install soundproof cover. Install the air filter housing.