Intake Manifold: Service and Repair

Removing and installing intake manifold, replacing gasket






Disconnect ground cable at battery.
Take off engine compartment panel.
Remove plastic rail (5) for engine wiring harness.
Remove mixture control unit with air guide housing.
Detach holder for starter cable (4).
Pull off vacuum connections at intake manifold and throttle valve body.
Remove vacuum line (1) for brake booster with holder (3).
Detach electrical connection and remove start valve (Y8).
Detach bowden cable for accelerator control or for automatic transmission.
Take off supporting bracket (2) for intake manifold.
Slacken at crankcase and take off both supporting brackets at intake manifold.

Note: On vehicles with Tempomat cruise control, take off bracket with Tempomat cruise control.

Take off protective cap at ignition coil.
On vehicles with level control take off suction hose by slackening hose clip and detaching hose clip from line.
Unscrew bolts (6) and nuts (7).
Pull off intake manifold (10).

Installation note:
Clean intake manifold and flange faces.
Check flange faces with straight edge, dress on dressing plate if necessary.
Torque manifold nuts (7) and bolts (6) starting in the center and moving outwards

Replace intake manifold gasket (12).
Adjust accelerator control linkage.
Check and adjust idle speed if needed.
Check intake system for leaks by spraying.






Note: Models 124, 126, 201
Installation of asbestos free intake manifold gasket.









Note: Modified attachment of intake manifold.
Stud bolt with spring washer and nut replaced by M8 x 45mm bolt + washer between cylinders 4 and 5.