Replace intake manifold gasket (Z 12 XE, Z 12 XEP,
Z 14 XEP, with air conditioning, LHD)
Note: In vehicles as
of model year 04 onwards with ESP - the steering angle sensor loses
its basic adjustment each time the battery is disconnected, and
must be recalibrated
Remove
4. |
Drain coolant
• |
Place collecting basin underneath.
|
• |
Open drain bolt (arrow)
|
|
|
|
6. |
Remove suction pipe
• |
Detach engine vent hose (3)
|
• |
Remove air intake hose (1)
|
• |
For Z 12 XEP, Z 14 XEP: detach air intake hose
|
|
|
|
Important: Observe safety
precautions and national regulations
|
7. |
Release fuel pressure with KM-J-34730-91
• |
Unscrew test connection protective cap (2) from fuel rail
(1)
Note: Test connection
is on top of fuel rail in Z 12 XEP and Z 14 XEP
|
|
|
|
8. |
Detach fuel rail (arrow) with KM-796-A
|
|
|
9. |
Detach coolant hoses
• |
Detach 2 throttle valve module preheater hoses (1)
|
• |
Detach coolant hose (2) from coolant pump
|
|
|
|
10. |
Detach engine vent hose from cylinder head
|
11. |
Unclip brake servo vacuum line (3)
|
|
|
12. |
Pull fuel evaporation hose (1) from intake manifold
|
13. |
Remove wiring harness for engine management
• |
For Z 12 XEP, Z 14 XEP: remove fuel rail cover
|
• |
Disconnect 5 wiring harness plugs
– |
Injection valves (3), throttle valve module (2)
|
|
• |
Disconnect engine control unit wiring harness plug
– |
Release in direction of arrow
|
|
• |
Remove ground cable (1)
|
• |
Unclip wiring trough (4)
|
• |
Set wiring harness to one side
|
|
14. |
Detach engine wiring harness
|
|
|
16. |
Detach engine wiring harness
|
17. |
Unclip wiring harness for engine management
|
|
|
19. |
Detach wiring harness bracket
• |
Remove engine transport shackle
|
• |
Set wiring harness to one side
|
|
20. |
Detach exhaust gas recirculation pipe from exhaust gas
recirculation coolant flange
• |
Unscrew 2 bolts (arrows)
|
|
21. |
Remove intake manifold
• |
Unscrew 6 nuts (arrows)
|
|
22. |
Clean sealing surfaces
|
|
|
Install
23. |
Install intake manifold
|
24. |
Attach exhaust gas recirculation pipe
|
25. |
Attach wiring harness for engine management
• |
Connect wiring harness for engine management
– |
Connect 7 wiring harness plugs
|
|
• |
For Z 12 XEP, Z 14 XEP: attach fuel rail cover
|
|
|
|
26. |
Install wiring harness bracket
• |
Insert engine transport shackle
|
|
27. |
Fasten engine wiring harness
|
28. |
Attach brake servo vacuum line
Note: Connection must
audibly engage
|
29. |
Attach fuel evaporation hose
|
30. |
Attach engine vent hose
|
32. |
Attach fuel line
• |
Attach fuel line
Note: Connection must
audibly engage
|
|
33. |
Install suction pipe
• |
Attach engine vent hose
|
• |
For Z 12 XEP, Z 14 XEP: attach air intake hose
|
|
35. |
Clip in engine management wiring harness
|
36. |
Fasten engine wiring harness
|
37. |
Close coolant drain bolt
|
40. |
Top up and bleed cooling system – see operation "Cooling
System, Top up and Bleed"
|
41. |
Program volatile memory
|
|