Intake Manifold, Remove and Install (16 LZ2)
 Important! Fuel escapes - observe safety measures and national legislation. Collect escaping fuel in a suitable container. Fuel system is pressurised.
 Remove, Disconnect Remove fuel pump relay - see operation "Fuel Pump Relay, Remove and Install". Start engine for at least 5 sec - fuel pressure reduction. Remove lower coolant hose from radiator. Collect escaping coolant. Detach vacuum hoses (1) from air intake cover (2). Remove engine vent hose (3) from camshaft housing cover. Remove air intake hose (4) from air cleaner housing. Remove air intake cover (2) from throttle valve injection housing. Remove air cleaner housing - see illustration "Air Cleaner Housing, Air Flow Guide (16 LZ2)". Note running direction of ribbed V-belt. Tension ribbed V-belt clockwise using ribbed V-belt tension roller and KM-913-A and remove ribbed V-belt from pulleys. | 
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Remove, Disconnect Disconnect wiring harness plug (1) from coolant temperature sensor. Disconnect wiring harness plug (2) from throttle valve potentiometer. Disconnect wiring harness plug (6) from injection valve and wiring harness plug (7) from idle speed stepper motor. Remove brake servo vacuum line (5) from intake manifold. Disconnect vacuum hose intake pipe pressure sensor (9) from intake manifold. Disconnect throttle valve control Bowden cable (8) and lay aside. Remove fuel lines (3) and (4) from throttle valve injection housing. | 
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Remove, Disconnect Remove support (2) and shackle (3) with wiring trough bracket from intake manifold and from alternator. Release lower alternator fastening bolt (4) and swing alternator to the rear. Detach coolant hoses (5) and engine vent hose (1) from intake manifold. Remove intake manifold from cylinder head.
 Clean Remove gasket remnants and clean sealing surfaces.
 Install, Connect Attach intake manifold to cylinder head with new gasket and new fastening nuts - tightening torque 22 Nm / 16 lbf. ft. Attach engine vent hose (1) and coolant hoses (5) to intake manifold. Attach support (2) and shackle (3) with wiring trough bracket to intake manifold and alternator - tightening torque 20 Nm / 15 lbf. ft. Tighten lower alternator fastening bolt (4) - tightening torque 35 Nm / 26 lbf. ft. | 
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Install, Connect Install fuel lines (3) and (4) at throttle valve injection housing - 15 Nm / 11 lbf. ft. Attach throttle valve control Bowden cable (8). Attach vacuum hose for intake pipe pressure sensor (9) to intake manifold. Attach brake servo vacuum line (5) to intake manifold - tightening torque 18 Nm / 13 lbf. ft. Connect wiring harness plug (1) to coolant temperature sensor, wiring harness plug (2) to throttle valve potentiometer, wiring harness plug (6) to injection valve and wiring harness plug (7) to idle speed stepper motor. Tension ribbed V-belt tension roller clockwise with KM-913-A and position ribbed V-belt - note running direction of ribbed V-belt. |
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Notice: Before assembling components of the intake system (hoses, connections, etc.), they must be cleaned of any possible contamination (grease, oil, etc.). When tightening the hose clamps, be sure to observe exactly the tightening torque of 3.5 Nm / 2.6 lbf. ft.
Important! It is only ensured that the intake system is free of leaks, thus ensuring operational safety of the engine, if the hose clamps are tightened correctly to the prescribed tightening torque.
Install, Connect Install air cleaner housing - see illustration "Air Cleaner Housing, Air Flow Guide (16 LZ2)". Attach air intake cover (2) to throttle valve injection housing, vacuum hoses (1) to air intake cover (2), engine vent hose (3) to camshaft housing cover and air intake hose (4) to air cleaner housing. |
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Install, Connect Install lower coolant hose on radiator. Install fuel pump relay - see operation "Fuel Pump Relay, Remove and Install".
 Inspect Top up cooling system - see operations "Cooling System, Top up and Bleed" and "Cooling System, Check for Leaks".
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