Intake Manifold, Remove and Install
 Remove, Disconnect Disconnect wiring harness plug (1) from intake air temperature sensor and wiring harness plug (2) from hot film mass air flow meter. Detach engine vent hoses (3) from cylinder head cover and air intake hose (4) from throttle body. Remove upper part of air cleaner housing with air intake hose. Connect Fuel Pressure Gauge KM-J-34730-91 to test connection on fuel distributor pipe. Reduce fuel pressure by opening valve on pressure gauge - collect escaping fuel in suitable container. Observe safety precautions and national regulations. Detach fuel return line (5) from fuel pressure regulator and detach Bowden cable bracket. Detach fuel feel line (6) from fuel distributor pipe and set aside to rear. Remove retainer for accelerator Bowden cable and unclip Bowden cable (7) from ball head. If equipped: remove retainer for cruise control Bowden cable and take cruise control Bowden cable out of ball head. Remove Bowden cable bracket (8) from throttle body and lay aside to the rear with Bowden cables. | 
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Remove, Disconnect Disconnect ignition cable cover (1) and disconnect wiring harness plug from camshaft sensor. Disconnect all wiring harness plugs or cable connections which are connected with plug strip or cable bundle (3). Press retaining clamp for injectors 1st cylinder and 4th cylinder (arrows) away from engine side in plug strip (with screwdriver) and pull plug strip upwards - lay plug strip with wiring loom aside to rear. Detach vacuum hose from tank vent valve - when detaching the vacuum hose from the valve body, ensure that the valve connection is not damaged. Damaged valves must be replaced.
 Important! Damaged valve connections may lead to vehicle fires as a result of leaks.
Remove, Disconnect Detach brake servo vacuum line from intake manifold. | 
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Remove, Disconnect For X 18 XE, X 20 XEV: disconnect or remove vacuum hose for exhaust gas recirculation valve from inlet manifold and vacuum hose from secondary air solenoid valve. Seal coolant hoses (2) with commercially available hose clamps and disconnect from throttle body - collect escaping coolant if necessary. |
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Remove, Disconnect Mark running direction of ribbed V-belt. Tension ribbed V-belt tension roller using KM-913-A in direction of arrow (clockwise) and remove ribbed V-belt from pulleys. Remove alternator support (1) and alternator shackle (2). Detach intake manifold support from intake manifold. Only release intake manifold support on cylinder block and pivot intake manifold support to the side (accessible from vehicle underside). Detach throttle body from intake manifold (4 fastening nuts).. Remove inlet manifold from cylinder head and take out upwards.
 Clean Remove gasket remnants and clean sealing surfaces. | 
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 Install, Connect Transfer attaching parts when replacing intake manifold. Attach inlet manifold with new seal to cylinder head - tightening torque 22 Nm / 16 lbf. ft. Attach throttle body to intake manifold with new gasket - tightening torque 9 Nm / 7 lbf. ft. Attach inlet manifold support to cylinder block and inlet manifold - tightening torque 25 Nm / 18 lbf. ft. Attach alternator support to alternator and intake manifold - tightening torque 20 Nm / 15 lbf. ft. Attach alternator shackle to alternator, intake manifold and coolant flange - tightening torque 20 Nm / 15 lbf. ft. Tension ribbed V-belt tension roller clockwise with KM-913-A and install ribbed V-belt - note running direction and installation position of ribbed V-belt. Attach/install coolant hoses and vacuum hoses or vacuum lines. Remove commercially available hose clamps. Connect plug strip to injectors - plug strip must engage audibly - ensure correct seating. Connect all disconnected wiring harness plugs - note cable routing.
Install, Connect Remove ignition cable cover - tightening torque 3 Nm / 2 lbf. ft. Connect Bowden cable bracket to throttle body and connect Bowden cables to ball head and secure. Connect fuel return line to fuel pressure regulator and Bowden cable bracket and fuel supply line to fuel distributor pipe - tightening torque 15 Nm / 11.1 lbf. ft. 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 Attach air intake hose to throttle body and engine vent hoses to cylinder head cover. Connect wiring harness plugs to intake air temperature sensor and to hot film mass air flow meter. Install air filter housing upper part. Top up cooling system - see operations "Cooling System, Top up and Bleed" and "Cooling System, Check for Leaks".
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