Intake Manifold, Remove and Install (C 14 SE, C 16 SE and C 20 NE) Notice: Operation is described for C 16 SE. For C 14 SE and C 20 NE, proceed analogously.
 Important! Fuel escapes - observe safety and local regulations. Fuel system is under pressure. Remove fuel pump relay - see operation "Fuel Pump Relay, Remove and Install". Start engine at least 5 sec. - fuel pressure reduction.
 Remove, Disconnect Detach air intake hose (1) and engine vent hoses (2) from throttle body. Air cleaner housing - see operation "Air Cleaner Housing, Remove and Install". Remove lower coolant hose from radiator - collect coolant. | 
|
Remove, Disconnect Detach accelerator Bowden cable (1) and brake servo vacuum line (3) from intake manifold. Detach wiring harness plug (2) from intake air temperature sensor and wiring harness plug (4) from injectors. Detach wiring harness plug from coolant temperature sender. Detach wiring harness plug (5) from throttle valve potentiometer and wiring harness plug (6) from idle speed stepper motor - note cable routing. Detach fuel lines - before removal, mark allocation and close off with spring clamps. | 
|
Remove, Disconnect For engines from MY '93: mark direction of motion of the ribbed V-belt. Remove tension from ribbed V-belt by means of ribbed V-belt tension roller and KM-913-A in clockwise direction and remove ribbed V-belt. Loosen fastening bolts (1) and (2), remove fastening bolts (3) and (4) from generator. Loosen lower alternator fastening bolt and swing alternator to the rear. | 
|
Engines with V-belt: detach V-belt from alternator. Detach alternator shackle from intake manifold. Loosen lower alternator fastening bolt - swing alternator backwards. | 
|
Remove, Disconnect Detach coolant hose from intake manifold. Detach coolant hoses and vacuum hoses from throttle body. Detach ground connections from intake manifold. Remove intake manifold from cylinder head.
 Clean Clean sealing surfaces and remove gasket residue.
 Install, Connect Attach intake manifold to cylinder head with new gasket - tightening torque 22 Nm/16 lbf. ft. Attach ground connections to intake manifold - ensure correct seating. Attach coolant and vacuum hoses to throttle body and intake manifold. | 
|
Install, Connect Attach fuel lines - note allocations. For engines from MY '93: Install support and strap on induction manifold and generator - tightening torque 18 Nm. Tighten lower generator fastening bolt - tightening torque 35 Nm. Place ribbed V-belt in position - tension ribbed V-belt by means of ribbed V-belt tension roller and KM-913-A. Note direction of motion of the ribbed V-belt. Engines with V-belt: install V-belt - see operation "V-belt, Remove and Install". Connect wiring harness plugs to idle speed stepper motor, throttle valve potentiometer, coolant temperature sender, intake air temperature sensor and injectors. Attach brake servo vacuum line to intake manifold - 20 Nm/15 lbf. ft. Attach accelerator Bowden cable to throttle body. | 
|
Install, Connect Install lower coolant hose at radiator. Air cleaner housing - see operation "Air Cleaner Housing, Remove and Install". Attach air intake hose and engine vent hoses to throttle body. Install fuel pump relay - see operation "Fuel Pump Relay, Remove and Install". Top up cooling system - see operation "Cooling System, Top Up and Bleed" and "Cooling System, Check for Leaks".
|
