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Intake Manifold, Remove and Install
 Remove
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Disconnect ground cable from battery. Open coolant drain bolt on
radiator – collect coolant.
For X 20 XEV: Disconnect wiring harness plug (1) from intake air
temperature sensor.
Disconnect wiring harness plug (2) from hot film mass air
flowmeter.
Remove crankcase ventilation hose (3) from cylinder head cover
and air intake hose from throttle body and air cleaner housing.
Remove ribbed V-belts – see operation "Ribbed V-belts,
Remove and Install".
Remove support (4) and shackle (5) from intake manifold and
alternator. Loosen lower alternator fastening bolt – swing
alternator aside.
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For X 20 XEV: Disconnect wiring harness plug (1) from throttle
valve potentiometer.
For Y 22 XE and Z 22 XE: Disconnect wiring harness plug from
throttle body – see operation "Throttle Body, Remove and
Install (Y 22 XE, Z 22 XE)".
Remove crankcase ventilation hose from cylinder head cover.
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For X 20 XEV: Disconnect wiring harness plug (1) from idle speed
stepper motor and ground strap (2) from fuel distributor pipe.
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Press retaining clip for injectors for 1st cylinder and 4th
cylinder in plug strip towards engine side (with screwdriver)
– collect retaining clips with bar magnet.
Lift plug strip (1).
For X 20 XEV: Disconnect crankshaft pulse pick-up (2) and knock
sensor (3) from the plug strip.
For Y 22 XE and Z 22 XE: Disconnect crankshaft pulse pick-up
wiring harness plug and knock sensor outside the plug strip.
Lay plug strip aside on cylinder head cover.
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Caution
Fuel escapes. Observe safety regulations and national
legislation.
Depressurise fuel using Fuel Pressure Gauge KM-J-34730-91 via
test connection (1) – collect escaping fuel in suitable
container.
Remove
Detach fuel lines from fuel distributor pipe.
For X 20 XEV: Remove Bowden cable (2) from Bowden cable
bracket.
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For version with X 20 XEV and cruise control. Remove fuel line
adapter bracket (1) from throttle body.
For X 20 XEV: Detach coolant hoses (2) from throttle body.
For Y 22 XE and Z 22 XE: Disconnect coolant hoses from throttle
body – see operation "Throttle Body, Remove and Install (Y 22
XE, Z 22 XE)".
Detach vacuum hose for tank vent valve on throttle body.
Remove fastening bolts (3) from intake manifold and remove
throttle body from intake manifold.
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For version with X 20 XEV and cruise control. Remove cruise
control Bowden cable (1) from ball head. Press together clip (2)
and remove cruise control Bowden cable from Bowden cable
bracket.
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Detach brake servo vacuum line (1) from intake manifold.
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Detach coolant hose (1) from coolant flange.
Remove intake manifold support from intake manifold, release
lower fastening bolt and swing support to the side.
Remove intake manifold from cylinder head.
 Clean
Clean sealing surfaces and remove gasket remnants.
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Install
Attach intake manifold with new gasket to cylinder head –
tightening torque 22 Nm / 16 lbf. ft. 1) .
Attach intake manifold support to intake manifold and cylinder
block – tightening torque 25 Nm / 18 lbf. ft.
Attach coolant hose to coolant flange.
Attach brake servo vacuum line to intake manifold –
tightening torque 20 Nm / 15 lbf. ft.
For version with X 20 XEV and cruise control. Press cruise
control Bowden cable in Bowden cable bracket and attach to ball
head.
Attach throttle body to intake manifold with new gasket –
tightening torque 9 Nm / 7 lbf. ft.
Connect vacuum hose for tank vent valve to throttle body. Attach
coolant hoses to throttle body.
For version with X 20 XEV and cruise control. Attach fuel line
adapter bracket to throttle body.
For X 20 XEV: Attach Bowden cable to Bowden cable bracket.
Attach fuel lines to fuel distributor pipe – tightening
torque 15 Nm / 11 lbf. ft.
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For Y 22 XE and Z 22 XE: Connect knock sensor wiring and
crankshaft pulse pick-up outside the plug strip.
For X 20 XEV: Connect knock sensor wiring harness (1) and
crankshaft pulse pick-up to plug strip. Note knock sensor cable
routing – cable runs between 3rd and 4th cylinders of intake
manifold.
Caution
If the spring clips (2) for the injectors are incorrectly
positioned, this will prevent the plug strip from engaging. Align
all spring clips properly so that correct plug strip contact with
the injectors is guaranteed. Connect plug strip to injectors
– ensure correct seating. Plug strip must engage audibly.
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Install
For X 20 XEV: Attach ground strap to fuel distributor pipe.
Attach wiring harness plug to idle speed stepper motor.
Attach crankcase ventilation hose to cylinder head cover.
For Y 22 XE and Z 22 XE: Attach wiring harness plug to throttle
body – see operation "Throttle Body, Remove and Install (Y 22
XE, Z 22 XE)".
For X 20 XEV: Attach wiring harness plug to throttle valve
potentiometer.
Attach support and shackle to intake manifold and alternator
– tightening torque 20 Nm / 15 lbf. ft. Tighten lower
alternator fastening bolt – tightening torque 35 Nm / 26 lbf.
ft.
Install ribbed V-belt – see operation "Ribbed V-belt,
Remove and Install".
Attach air intake hose to throttle body and air cleaner housing
and crankcase ventilation hose to cylinder head cover. Attach
wiring harness plug to hot film mass air flowmeter.
For X 20 XEV: Attach wiring harness plug to intake air
temperature sensor.
Close coolant drain bolt on radiator. Connect ground cable to
battery.
Inspect
Top up and bleed cooling system – see operation "Cooling
System, Top up and Bleed" and "Cooling System, Check for
Leaks".
1 ) Use new nut(s).
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