For 1990-2009 cars

#### Special Tools

• | J 37088-A Fuel Line Disconnect Tool Set

• | KM-807 Closure Plugs

• | KM-J-34730-91 Pressure Tester

### Removal Procedure

1. Open the hood.

Caution: Refer to Battery Disconnect Caution in the Preface section.

2. Disconnect the battery.
3. Raise the vehicle by its full height.
4. Drain the coolant.

• | Place a drip pan underneath.

• | Connect a suitable hose to the drain connection (2).

• | Open the coolant drain screw (1).

• | Drain the coolant.

• | Close coolant drain screw.

5. Remove the intake manifold support (2).

• | Disconnect the wiring harness plug of the catalytic converter control oxygen sensor.

• | Remove the wiring harness plug (1) from the bracket.

• | Remove the 2 bolts (3).

6. Remove the wiring harness from the intake manifold.
7. Lower the vehicle by its full height.
8. Remove the air cleaner housing. Refer to Air Cleaner Assembly Replacement .
9. Disconnect the tank vent valve from the intake manifold.

• | Disconnect the wiring harness plug (2).

• | Disconnect the rubber mounting (3) from the bracket.

• | Disconnect the line (1) from the intake manifold.

• | Set the tank vent valve aside.

10. Place a drip pan underneath.
11. Release the fuel pressure via the test connection (1) using KM-J-34730-91 .

Collect exiting fuel in a suitable container - observe safety regulations and national legislation.

12. Remove the fuel return line (1).

• | Remove the quick-release fitting with J 37088-A .

• | Seal the fuel line and fuel rail with KM-807 .

13. Remove the engine venting pipe (1).

• | Remove the wiring trough (2) from cylinder head cover.

• | Disconnect the 2 quick-release fittings.

14. Remove the engine control module. Refer to Engine Control Module Replacement .
15. Remove the engine management wiring harness.

• | Disconnect the 7 wiring harness plugs.

- | Air mass flow meter

- | Throttle valve module

- | Valve, intake camshaft adjustment

- | Four injector valves

• | Remove the 2 wiring harness brackets.

• | Put the wiring harness to side.

16. Disconnect the wiring harness plug (1).
17. Remove the supply line, fuel/air mixture preheating (1).

• | Disconnect from thermostat housing.

• | Disconnect the quick-release fitting.

• | Disconnect from the throttle valve module.

• | Release the clamp.

• | Disconnect from the intake manifold.

• | Remove 4 from bracket.

18. Remove the return line, fuel/air mixture preheating (2).

• | Remove from the throttle valve module.

• | Release the clamp.

• | Remove from the coolant expansion tank.

• | Release the clamp.

• | Remove from the intake manifold.

• | Remove the 3 brackets.

19. Disconnect the 2 wiring harness plugs.

• | Wiring harness plug, vacuum unit change-over valves (1)

• | Wiring harness plug, change-over valves for solenoid valve (2)

20. Disconnect the wiring harness bracket (1) from the engine transport shackle.

Remove the bolt (2).

21. Disconnect the brake servo vacuum line (1) from the intake manifold.

Disconnect the quick-release fitting.

22. Remove the throttle valve module.

Remove the 4 bolts (1).

23. Remove the intake manifold.

Remove the 7 bolts (1).

24. Remove the wiring harness bracket.

Remove the 2 bolts.

25. Fuel rail system

### Installation Procedure

1. Clean the sealing surfaces.
2. Insert the 4 new gaskets.

Notice: Refer to Fastener Notice in the Preface section.

3. Install the intake manifold.

Tighten
Tighten the 7 bolts to 20 N·m (16 lb ft).

4. Install the throttle valve module.

Use a new gasket.

Tighten
Tighten the 4 bolts to 9 N·m (80 lb in).

5. Install the brake servo vacuum line to the intake manifold.

Connect the quick release fitting.

6. Install the wiring harness bracket to the engine transport shackle.

Tighten
Tighten the bolt to 5 N·m (44 lb in).

7. Connect the 2 wiring harness plugs.

• | Vacuum unit change-over valves

• | Solenoid valve for change-over valves

8. Install the return line, fuel/air mixture preheating.

• | Connect the throttle valve module.

• | Fasten the clamp.

• | Connect the coolant expansion tank.

• | Fasten the clamp.

• | Install the intake manifold.

• | Install the 3 brackets.

9. Install the supply line, fuel/air mixture preheating.

• | Connect to the thermostat housing.

• | Connect the quick release fitting.

• | Install the throttle valve module.

• | Fasten the clamp.

• | Install the intake manifold.

• | Connect the 4 brackets.

10. Install the engine management wiring harness.

• | Connect the 7 wiring harness plugs.

- | Air mass flow meter

- | Throttle valve module

- | Valve, intake camshaft adjustment

- | Four injector valves

• | Clip on the 2 wiring harness brackets.

11. Install the engine control module. Refer to Engine Control Module Replacement .
12. Install the engine vent hose.

• | Connect the 2 quick-release fittings.

• | Clip the wiring harness to the cylinder head.

13. Install the fuel supply line to the fuel rail.

• | Remove KM-807 .

• | Connect the quick release fitting.

• | Install into the bracket.

14. Connect the tank vent valve to the intake manifold.

• | Connect the line to the intake manifold.

• | Connect the rubber mounting to the bracket.

• | Install the wiring harness plug.

15. Install the air cleaner housing. Refer to Air Cleaner Assembly Replacement .
16. Raise the vehicle by its full height.
17. Install the wiring harness to the intake manifold.
18. Install the intake manifold support.

Tighten
Tighten the 2 bolts to 8 N·m (71 lb in).

• | Connect the wiring harness plug into the bracket.

• | Connect the wiring harness plug for the catalytic converter control oxygen sensor.

19. Lower the vehicle by its full height.
20. Fill and bleed the cooling system. Refer to Cooling System Draining and Filling .
21. Connect the battery.
22. For programming procedures, refer to Control Module References .
23. Close the hood.