Intake Manifold, Remove and Install (X 12 XE)
Remove
Remove air cleaner housing with hot film mass air flow meter and
air intake cover – see illustration "Air Ducts X 12 XE".
Detach accelerator Bowden cable (1) from curved disc and
bracket.
Detach coolant hoses (2) from throttle body.
Reduce fuel pressure with Pressure Tester KM-J-34730-91 via
testing port (arrow) – collect escaping fuel in suitable
container – observe safety regulations and national
legislation.
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Detach fuel feed line (3) from fuel distributor pipe.
Detach engine vent hose (1) from cylinder head cover.
Disconnect wiring harness plug (4) from tank vent valve.
Remove vacuum hose for tank vent valve (2) from throttle
body.
Detach tank vent valve (5) from bracket and put to one side with
line.
Detach brake servo vacuum line (6) from intake manifold.
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Disconnect or detach following wiring
harness plugs.
1. |
Exhaust gas recirculation valve |
2. |
Ignition module |
3. |
Oil pressure switch |
4. |
Coolant temperature sensor |
5. |
Camshaft sensor |
6. |
Throttle valve adjuster |
7. |
Throttle valve potentiometer |
8. |
Engine control unit |
9. |
Earth cable |
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Detach throttle body (1) from intake manifold.
Remove fastening bolt (2) – put cable bunch bracket to one
side and remove engine transport shackle.
Disconnect injector plug strip (3) from intake manifold or fuel
distribution pipe (2 fastening bolts) and carefully remove from
injectors – spread fastening clips for this operation
(arrows).
Put plug strip with cable bunch to one side.
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Detach exhaust gas recirculation pipe (1) from exhaust gas
recirculation valve.
Detach intake manifold support (2) from cylinder block and
detach from intake manifold – twist support to one side.
Detach intake manifold (3) from cylinder head and remove
upwards.
Transfer attaching parts when replacing intake manifold.
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Clean
Clean sealing surfaces and remove gasket remnants.
Install
Attach intake manifold to cylinder head with new seal rings
– tightening torque 10 Nm / 7.5 lbf. ft.
Attach intake manifold support to intake manifold –
tightening torque 6 Nm / 4 lbf. ft.
Attach intake manifold support to cylinder block –
tightening torque 20 Nm / 15 lbf. ft.
Attach exhaust recirculation pipe to exhaust recirculation valve
with new gasket – tightening torque 8 Nm / 6 lbf. ft.
Connect injector plug strip to injectors – plug strip must
audibly engage.
Attach injector plug strip to intake manifold with fuel
distribution pipe – tightening torque 8 Nm / 6 lbf. ft.
Attach engine transport shackle to cylinder head with cable
bunch bracket – tightening torque 20 Nm / 15 lbf. ft.
Attach throttle body with new gasket to intake manifold –
tightening torque 8 Nm / 6 lbf. ft.
Connect or attach all wiring connections which are connected to
the injectors plug strip.
Attach brake servo vacuum line to intake manifold. Attach tank
vent valve to bracket – tightening torque 6 Nm / 4 lbf.
ft.
Attach vacuum hose for tank vent valve to throttle body.
Attach fuel feed lines to fuel distributor pipe –
tightening torque 15 Nm / 11 lbf. ft.
Attach engine vent hose to cylinder head cover. Attach coolant
hoses to throttle body. Attach accelerator Bowden cable to curved
disc and bracket.
Install air cleaner housing with hot film mass air flow meter
and air intake cover – see illustration "Air Ducts X 12
XE".
Inspect
Charge cooling system – see operations "Cooling System,
Charge and Bleed" and "Cooling System, Check for Leaks".
Note: When removing
and installing the throttle body, it is essential that the
adaptation values for the throttle valve in the EE PROM of the
engine control unit are deleted using TECH 2 – see
corresponding Checking Procedures.
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