For 1990-2009 cars only
Removal Procedure
- Remove the fuel pump, refer to Fuel Pump Replacement.
- Remove the EGR-Cooler refer to Exhaust Gas Recirculation Valve Cooler Removal
- Unplug the intake air sensor connector (1) and the glow plug connector (2).
- Remove the coolant connection (1).
- Detach the cable bracket 1 screw (1).
- Detach the exhaust pressure pipe, 1 electrical connector (2), 1 clamp (3) and remove the hose , 2 screw (4).
- Remove coolant quick connection (5).
- Remove the oil trap from the engine block,remove the upper hose connection (6). , remove the clips (7). Remove 2 bolts (8). And move the oil trap aside
- Unplug the connector (1) of the combustion circulation actuator.
- Remove the stud (1) holding the high-pressure pump in place. Lock two M8 nuts with each other and remove the bolt.
- Remove the bolt towards the lifting eye (1).
- Remove the intake manifold (2).
Installation Procedure
- Fit the intake manifold (2) with new seals. Tighten to 25 N·m(18 lb ft).
- Fit the bolt towards the lifting eye (1).
- Fit the stud (1).
- Plug in the connector (1) of the combustion circulation actuator.
- Mount the exhaust pressure pipe, 2 screws (4).1 electrical connector (2), 1 clamp (3) and attach the hose.
- Fit the oil trap to the engine block,attach the upper hose connection (6). , mount the clips (7). mount 2 bolts (8).
- Fit the coolant quick connection (5).
- Attach the cable bracket 1 screw (1).
- Plug in the intake air sensor connector (1) and the glow plug connectors (2).
- Fit the EGR-cooler, refer to Exhaust Gas Recirculation Valve Cooler Removal.
- Fit the Fuel Pump, refer to Fuel Pump Replacement.
- Connect an exhaust hose and start the engine. Check there are no leaks. Connect the diagnostic tool and clear any DTCs.
Caution: Refer to Fastener Caution in the Preface section.
