Inlet Manifold - Lower Part, Remove and Install (X 16 XEL with Secondary Air System)
 Remove, Disconnect Remove upper part of inlet manifold - see operation "Inlet Manifold - Upper Part, Remove and Install (X 16 XEL with Secondary Air System)". Remove air inlet manifold - see operation "Air Intake Manifold, Remove and Install (X 16 XEL with Secondary Air System)". Remove lower radiator hose from radiator - collect escaping coolant. Connect Fuel Pressure Gauge KM-J-34730-91 to test connection of fuel distributor pipe. Reduce fuel pressure by opening valve on pressure gauge. Collect escaping fuel in suitable container - observe safety regulations and national legislation. Remove fuel supply line (1) from fuel distributor pipe, fuel return line (2) from fuel pressure regulator and unions (3) from throttle body. Take wiring harness plug for crankshaft pulse pickup (4) out of bracket and pull through towards the bottom (between inlet manifold ducts) - note cable routing. Detach accelerator Bowden cable and lay aside. Remove throttle body from throttle body flange and lay downwards and aside. Disconnect wiring harness plug (5) from idle speed stepper motor and wiring harness plug (6) from throttle valve potentiometer. | 
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Remove, Disconnect Remove throttle body flange (1) from lower part of inlet manifold - note different bolt lengths. Remove fastening bolts (3) and take out alternator shackle (2). | 
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Remove, Disconnect Detach coolant hose from lower part of intake manifold (arrow). Remove lower part of intake manifold from cylinder head. Detach coolant flange (1) from cylinder head any lay to rear.
 Clean Remove gasket remnants and clean sealing surfaces.
 Install, Connect Attach coolant flange (1) and lower part of inlet manifold with new seal to cylinder head - tightening torque 20 Nm / 15 lbf. ft. Attach coolant hose to lower part of inlet manifold (arrow) - ensure correct seating. | 
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Install, Connect Secure alternator shackle to coolant flange, alternator and lower part of intake manifold - tightening torque 20 Nm / 15 lbf. ft. Attach throttle body flange to lower part of intake manifold - note different bolt lengths - tightening torque 8 Nm / 6 lbf. ft. Attach wiring harness plug to idle speed stepper motor and to throttle valve potentiometer. Attach throttle body to throttle body flange with new gasket - tightening torque 8 Nm / 6 lbf. ft. Attach accelerator Bowden cable. Pull through wiring harness plug for crankshaft pulse pickup between intake manifold ducts and latch into bracket - note cable routing.
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 Secure unions to throttle body with hose clamp. Install fuel supply line at fuel distributor tube and fuel return line at fuel pressure regulator. Attach lower radiator hose to radiator. Install upper part of inlet manifold - see operation "Inlet Manifold - Upper Part, Remove and Install (X 16 XEL with Secondary Air System)". Top up cooling system - see operations "Cooling System, Top up and Bleed" and "Cooling System, Check for Leaks".
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