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Intake Manifold, Replace (Z16XEP) > < All Valve Stem Seals, Replace

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Intake Manifold, Remove and Install

  Remove

1.   Open bonnet
2.   Disconnect earth cable from battery
•   Loosen bolt
3.   Remove air cleaner housing
•   Disconnect mass air flow sensor wiring harness plug (2)
•   Unclip tank vent line (3)
•   Detach engine vent hose (4) from air intake hose
– Release clamp
•   Detach air intake hose (5) from throttle valve body
– Release clamp
•   Detach air cleaner housing
– Unscrew bolt (1)
– Unclip rubber mounting at the bottom
– Remove air intake pipe (6)
Object Number: 3446127 Size: DEFAULT


4.   Disconnect throttle body wiring harness plug (2)
5.   Detach coolant hoses (1) from throttle valve body
•   Place collecting pan underneath.
•   Undo 2 clamps
6.   Unclip coolant hose (3)
Object Number: 3446288 Size: DEFAULT


7.   Release fuel pressure with KM-J-34730-91 (2) via test connection
•   Unscrew protective cap from test connection (1)
•   Collect escaping fuel in a suitable container
•   Comply with safety regulations and national legislation
Object Number: 3446128 Size: DEFAULT


8.   Detach fuel supply line (2) with KM-796 (1) from fuel distributor pipe
•   Disconnect quick-release fitting
9.   Detach brake servo vacuum line (3) from intake manifold
•   Disconnect quick-release fitting
Object Number: 3446129 Size: DEFAULT


10.   Remove cover - injectors (1)
•   Unscrew 2x bolts
11.   Detach hose, crankcase venting (2), from cylinder head cover
•   Release clamp
12.   Disconnect 4x wiring harness plug, injectors (3)
•   Set wiring harness aside to the left
Object Number: 3446289 Size: DEFAULT


13.   Remove wiring harness plug (2)
•   Detach in direction of arrow
14.   Remove wiring harness plug (3)
•   Open latch (4)
15.   Detach earth cable (1) from engine control unit
•   Unscrew bolt
Object Number: 3446290 Size: DEFAULT


16.   Detach EGR pipe from exhaust gas recirculation valve
•   Unscrew 2x bolts (arrows)
Object Number: 2410466 Size: DEFAULT


17.   Detach tank vent valve hose (1) from intake manifold
Object Number: 3446126 Size: DEFAULT


18.   Disconnect tank vent valve wiring harness plug (1)
Object Number: 3446292 Size: DEFAULT


19.   Expose engine wiring harness
•   Open 4x clips
20.   Remove intake manifold
•   Unscrew 6x bolts (1)
•   Take out intake manifold upwards
•   Remove 4x seal rings
Object Number: 3446291 Size: DEFAULT


21.   Clean sealing surfaces.

  Install

22.   Install intake manifold
•   Insert 4x new seal rings
•   Tighten 6x bolt 10 Nm
23.   Fasten engine wiring harness
•   Clip in 4x
24.   Attach brake servo vacuum hose to throttle valve body
25.   Attach tank vent valve hose to throttle body
26.   Connect wiring harness plug, tank vent valve
27.   Attach EGR pipe to EGR valve
•   Tighten 2x bolt 8 Nm
28.   Attach earth cable to engine control unit
•   Tighten bolt
29.   Connect 2x wiring harness plug, engine control unit
30.   Connect 4x wiring harness plug, injectors
31.   Attach hose, crankcase venting, to cylinder head cover
32.   Attach fuel supply line to fuel rail
33.   Attach coolant hoses to throttle valve body
•   Attach 2x clamps
34.   Connect wiring harness plug, throttle valve body
35.   Install air cleaner housing
•   Tighten bolt
•   Connect air intake hose
– Attach 2x clamps
•   Attach engine vent hose
– Fasten clamp
•   Connect 2x wiring harness plugs
– Hot film air mass flow meter, tank vent valve
36.   Fill and bleed cooling system LUREF_1.gif
37.   Close bonnet

Intake Manifold, Replace (Z16XEP) > < All Valve Stem Seals, Replace