Intake Manifold, Remove and Install (X 16 XEL without Secondary Air System)
 Remove, Disconnect Remove air filter casing - see diagrams "Air Filter Casing, Air Flow Guide". Detach engine cover (4) and engine vent hoses (3) from cylinder head cover. Mark running direction of ribbed V-belt. Tension ribbed V-belt with ribbed V-belt tension roller and KM-913-A clockwise and take ribbed V-belt out of pulleys. Detach wiring harness plug (1) from intake air temperature sensor and detach air intake hose (2) from upper part of air cleaner housing and throttle body. Disconnect/detach all cable connections connected to the wiring loom or plug strip (5). | 
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 Important! Fuel escapes - observe safety measures and national legislation. Connect Fuel Pressure Gauge KM-J-34730-91 to test connection on fuel distributor pipe. Reduce fuel pressure by opening valve on fuel pressure gauge.
Remove, Disconnect Detach vacuum line (1) from fuel pressure regulator. Detach fuel feed line (3) from fuel distributor pipe and fuel return line (2) from fuel pressure regulator. Unscrew fastening bolts (arrows) for fuel distributor pipe. Carefully pull fuel distributor pipe together with plug strip and injection valves out of inlet manifold flange. | 
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Remove, Disconnect Detach brake servo vacuum line (1) from intake manifold. Remove vacuum hose for tank vent valve (2) from throttle body. Detach coolant hoses (3) from throttle body - collect escaping coolant. Detach vacuum hose for intake pipe pressure sensor (4) from intake manifold. Detach accelerator Bowden cable (5) and lay aside to the rear. | 
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Remove, Disconnect Remove alternator shackle (1) from alternator, cylinder head and inlet manifold (arrows) and take out. Unscrew fastening bolts (arrows) and remove reaction member (2). | 
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Remove, Disconnect Unbolt alternator support (1) (arrows) and remove upwards. Loosen lower alternator fastening bolt and swing alternator aside. Remove inlet manifold support from inlet manifold and cylinder block (accessible from vehicle underside). Notice: For clearer representation, illustration J 0005 shows the intake manifold removed.
Remove, Disconnect Remove fastening bolts (2) and remove inlet manifold from inlet manifold flange.
 Clean Remove gasket remnants and clean sealing surfaces. | 
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 Install, Connect Transfer attaching parts when replacing intake manifold. Attach intake manifold to intake manifold flange with new gasket - tightening torque 8 Nm / 6 lbf. ft. Attach intake manifold support to intake manifold - tightening torque 20 Nm / 15 lbf. ft. Attach intake manifold support to cylinder block - tightening torque 35 Nm / 26 lbf. ft. Insert alternator support and fasten - tightening torque 35 Nm / 26 lbf. ft. Hand-tighten lower alternator fastening bolt - tightening to torque only takes place after the alternator shackle has been installed. Install reaction member and tighten fastening bolts - tightening torque 60 Nm / 44 lbf. ft. Secure alternator shackle to coolant flange, alternator and inlet manifold flange - tightening torque 20 Nm / 15 lbf. ft. Tighten lower alternator fastening bolt - tightening torque 35 Nm / 26 lbf. ft. Carefully insert injectors with new seal rings together with wiring trough and fuel distributor pipe and secure - tightening torque 8 Nm / 6 lbf. ft. Attach fuel lines to fuel distributor pipe and to fuel pressure regulator. Attach coolant hoses to throttle body.
Install, Connect Attach brake servo vacuum line and vacuum hose for intake pipe pressure sensor to intake manifold. Attach vacuum hose for tank vent valve to throttle body. Connect vacuum hose for secondary air switchover valve. Attach accelerator Bowden cable in ball head and bracket without tension. Connect plug strip to injectors - plug strip must engage audibly - ensure correct seating. Connect/attach all cable connections connected with the wiring loom or plug strip. 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 Connect air intake hose to throttle valve connection.
Install, Connect Attach engine vent hoses to cylinder head cover. Connect wiring harness plug to intake air temperature sensor. Install engine cover on cylinder head cover. Tension ribbed V-belt tension roller clockwise with KM-913-A and position ribbed V-belt - note running direction of ribbed V-belt. Install air cleaner housing - see illustrations "Air Cleaner Housing, Air Flow Guide". Top up cooling system - see operations "Cooling System, Top up and Bleed" and "Cooling System, Check for Leaks".
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