Intake Manifold - Lower Part, Remove and Install (X 14 XE, C 14 SEL, X 16 XE, C 16 SEL)
 Important! Fuel system is pressurised: Reduce fuel pressure with Pressure Tester KM-J-34730-91 via testing port - collect escaping fuel in suitable container - observe safety regulations and national legislation.
 Remove, Disconnect Remove upper part of intake manifold - see operation "Intake Manifold - Upper Part, Remove and Install (X 14 XE, C 14 SEL, X 16 XE, C 16 SEL)". Depressurise cooling system by opening of closure cap on coolant compensation tank. Close off fuel feed line (1, see illus. I) from fuel distributor pipe and fuel return line (2, see illus. I) from fuel pressure regulator with commercially available hose clamps and detach. Unclip wiring harness plug for camshaft pulse pick-up (1, see illus. II) out of bracket. Detach wiring harness plug for inductive pulse pick-up (2, see illus. II). Release retaining spring using screwdriver and pull plug housing out of bracket (see detail). Detach vacuum hose (3, see illus. II) from fuel pressure regulator. | 
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Remove, Disconnect Disconnect combination plug (1) and release combination plug bracket from alternator shackle (arrow). | 
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Disconnect wiring harness plugs from injectors. Detach fuel distributor pipe from lower part of intake manifold. (2 bolts) and remove upwards together with injectors. Detach connection hose (1) from throttle body. Detach Bowden cable (2) from throttle body and set aside. | 
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Remove, Disconnect Detach air intake pipe from wiring trough bracket. Release hose clamp and detach air intake pipe downwards from throttle body. Detach throttle body from throttle body bracket (1). Detach throttle body mounting flange from lower part of intake manifold (2). Detach wiring trough from wiring trough bracket and unclip wiring harness plug. Detach wiring trough bracket from lower part of intake manifold (3) and remove. | 
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Remove, Disconnect Disconnect wiring harness plug from exhaust gas recirculation valve and detach exhaust gas recirculation valve from lower part of intake manifold (1). Remove rear engine transport shackle. Remove intake air temperature sensor from air intake pipe. Remove air intake pipe towards transmission side (2). Remove lower part of intake manifold from cylinder head (arrows, see illus. III). Remove coolant hose from lower part of intake manifold and remove lower part of intake manifold. Collect escaping coolant in suitable container.
 Clean Remove old gaskets and clean sealing surfaces. | 
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 Install, Connect Attach coolant hose (1) to lower part of intake manifold. Attach lower part of intake manifold to cylinder head with new gasket.
 Tighten (Torque) Lower part of intake manifold to cylinder head - 20 Nm / 15 lbf. ft. 1) . | 
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Install, Connect Install air intake pipe from transmission side (see illus.). Insert intake air temperature sensor into air intake pipe. Attach exhaust gas recirculation valve (20 Nm / 15 lbf. ft.) with new gasket and wiring trough bracket (8 Nm / 6 lbf. ft.) to lower part of intake manifold. Connect wiring harness plug to exhaust gas recirculation valve, insert wiring trough and wiring harness plug into bracket. | 
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1) Use new fastening nut(s).
Install, Connect Attach engine transport shackle to cylinder head - 25 Nm / 18 lbf. ft. Attach throttle body mounting flange to lower part of intake manifold - 8 Nm / 6 lbf. ft. Fasten throttle body to mounting flange with new gasket (arrows) - 8 Nm / 6 lbf. ft. | 
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Attach Bowden cable (2) and connection hose (1) to throttle body. Attach air intake pipe to throttle body. |
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Install, Connect Insert injection valves together with fuel distributor pipe into intake manifold - 8 Nm / 6 lbf. ft. Coat O-rings thinly with silicone grease (white).
Important! The injectors must always remain in a exactly defined installation position. Turning about the longitudinal axis leads to inferior exhaust gas emission values. In order to fix injectors in the optimum position, sheet metal tabs are fitted to the fuel distributor pipe adjacent to each injector, which permit only one installation position (see illus. I).
Install, Connect Attach combination plug bracket to alternator shackle (arrow, see illus. II). Connect combination plug (1).
Tighten (Torque) Combination plug bracket to alternator shackle - 20 Nm / 15 lbf. ft. | 
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Install, Connect Clip wiring harness plug for camshaft pulse pick-up (1) into bracket. Insert wiring harness plug for inductive pulse pickup (2) into bracket and connect. Attach vacuum hose (3) to fuel pressure regulator. | 
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Attach fuel feed line to fuel distributor pipe and fuel return line to fuel pressure regulator. Attach wiring harness plug to injectors. Install upper part of intake manifold - see operation "Intake Manifold - Upper Part, Remove and Install (X 14 XE, C 14 SEL, X 16 XE, C 16 SEL)". Top up (see illus.) and bleed cooling system - see corresponding operation. Ensure that anti-freeze is adequate to a temperature of -30 ° C / -22 ° F. | 
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