Intake Manifold, Remove and Install (20 NEJ)
 Remove, Disconnect Remove lower coolant hose from radiator. Collect escaping coolant. Detach wiring harness plug (2) from hot film air mass sensor and wiring harness plug (3) from intake air temperature sensor. Remove air intake hose (1) from throttle body and upper part of air cleaner housing (4). Remove air cleaner housing (4) - see illustration "Air Cleaner Housing, Air Flow Guide (20 NEJ)". Mark 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 Remove torque support bracket (1). Detach brace (2) and shackle (3) with cable bundle bracket (4) from intake manifold and alternator. Release lower alternator fastening bolt and tilt alternator backwards. | 
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 Important! Fuel outlet, note safety regulations and national legislation. Connect Fuel Pressure Gauge KM-J-34730-91 at testing port of fuel distributor pipe. Reduce fuel pressure by opening valve on pressure gauge - collect escaping fuel in suitable container.
Remove, Disconnect Disconnect throttle valve control Bowden cable (2) at Bowden cable bracket (1) and lay aside. Detach brake servo vacuum line (3) from intake manifold. Detach engine vent hose (6) from throttle body. Detach fuel lines (4) and (5) from fuel distributor pipe. Detach or remove all wiring harness plugs for Motronic M 1.5.4 - see illustration "Cable Routing - Motronic M 1.5.4". Remove wiring trough from camshaft housing and lay aside. | 
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Remove, Disconnect Remove engine bleeding hose (1) from camshaft housing cover. Detach vacuum hoses (2) from tank vent valve - when detaching the vacuum hoses (2) from the valve body, ensure that the valve connections are not damaged. Close off vacuum hose to activated carbon canister.
Important! Damaged valve connections may lead to vehicle fires as a result of leaks.
Remove, Disconnect Detach coolant hoses (3) from throttle body. Remove intake manifold from cylinder head.
 Clean Remove gasket remnants and clean sealing surfaces. | 
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 Install, Connect Attach intake manifold to cylinder head with new gasket and new fastening nuts - tightening torque 22 Nm / 16 lbf. ft. Attach coolant hoses (3) to throttle body. Attach vacuum hoses (2) to tank vent valve and engine vent hose (1) to camshaft housing cover. |
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Install, Connect Attach cable trough to camshaft housing cover - tightening torque 8 Nm / 6 lbf. ft. Connect/attach all wiring harness plugs for Motronic M 1.5.4 - see illustration "Wiring Harness Routing Motronic M 1.5.4". Attach fuel lines with new seal rings to fuel distributor pipe - tightening torque 15 Nm / 11 lbf. ft. Attach brake servo vacuum line to intake manifold - tightening torque 18 Nm / 13 lbf. ft. Attach throttle valve actuation Bowden cable. Attach engine vent hose to throttle body. Attach support (2) and shackle (3) with wiring harness bracket (4) to intake manifold and to alternator - tightening torque 20 Nm / 15 lbf. ft. Install lower alternator fastening bolt - tightening torque 35 Nm/ 26 lbf. ft. Attach torque support bracket (1) to torque support and to adapter for torque support bracket on cylinder block - tightening torque 60 Nm / 44 lbf. ft. |
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Install, Connect Tension ribbed V-belt tension roller clockwise with KM-913-A and position ribbed V-belt - note running direction of ribbed V-belt. 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 (4) - see illustration "Air Cleaner Housing, Air Flow Guide (20 NEJ)". Attach air intake hose (1) to throttle body and upper part of air cleaner housing (4). Connect wiring harness plug (2) to hot film mass air flow meter and wiring harness plug (3) to intake air temperature sensor. Install lower coolant hose on radiator.
 Inspect Top up cooling system - see operations "Cooling System, Top up and Bleed" and "Cooling System, Check for Leaks". |
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