For 1990-2009 cars

#### Special Tools

• | KM-796-A Dismantler

• | KM-807 Closure Plugs

• | KM-J-34730-91 Pressure Tester

• | J 37088-A Fuel Line Disconnect Tool Set

1. Drain the coolant.

1.1. | Place a drip pan underneath.

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

1.3. | Open the coolant drain screw (1).

1.4. | Drain the coolant.

1.5. | Close the coolant drain screw.

2. Remove the intake manifold support (2).

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

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

2.3. | Remove the 2 bolts (3).

3. Remove the wiring harness from the intake manifold.
4. Remove the air cleaner housing. Refer to Air Cleaner Assembly Replacement.
5. Disconnect the tank vent valve from the intake manifold.

5.1. | Disconnect the wiring harness plug (2).

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

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

5.4. | Set the tank vent valve aside.

6. Place a drip pan underneath.
7. Using the KM-J-34730-91 , release the fuel pressure via the test connection (1).

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

8. Remove the fuel return line (1).

8.1. | Using the J 37088-A , remove the quick-release fitting.

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

9. Remove the engine venting pipe (1).

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

9.2. | Disconnect the 2 quick-release fittings.

10. Remove the engine control module. Refer to Engine Control Module Replacement.
11. Remove the engine management wiring harness.

11.1. | Disconnect the 7 wiring harness plugs:

• | The air mass flow meter

• | The throttle valve module

• | The valve, intake camshaft adjustment

• | The 4 injector valves

11.2. | Remove the 2 wiring harness brackets.

11.3. | Place the wiring harness to the side.

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

13.1. | Disconnect from the thermostat housing.

13.2. | Disconnect the quick-release fitting.

13.3. | Disconnect from the throttle valve module.

13.4. | Release the clamp.

13.5. | Disconnect from the intake manifold.

13.6. | Remove 4 from bracket.

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

14.1. | Remove from the throttle valve module.

14.2. | Release the clamp.

14.3. | Remove from the coolant expansion tank.

14.4. | Release the clamp.

14.5. | Remove from the intake manifold.

14.6. | Remove the 3 brackets.

15. Unclip the wiring trough (2) from the cylinder head cover.
16. Disconnect the 2 quick-release fittings.
17. Remove the engine venting pipe (1).
18. Remove the engine management wiring harness.

18.1. | Disconnect the following 9 wiring harness plugs:

- | Engine control unit

- | Air mass flow meter

- | Tank vent valve

- | Throttle valve module

- | Valve, intake camshaft adjustment

- | 4 injector valves

18.2. | Unclip 2 wiring harness brackets.

18.3. | Put the wiring harness to the side.

19. Place a collecting basin underneath.
20. Using the KM-J-34730-91 , release fuel pressure via the test connection (1).

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

21. Using the KM-796-A , undo the quick-release fitting.
22. Using the KM-807 , seal the fuel line and fuel rail.
23. Remove the fuel return line (1).
24. Remove the 2 fuel rail bolts (1) and the fuel rail (2).
25. Remove the 4 retaining clamps (1) and the injectors.
26. 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)

27. Disconnect the wiring harness bracket (1) from the engine transport shackle.
28. Remove the bolt (2).
29. Disconnect the brake servo vacuum line (1) from the intake manifold.

Disconnect the quick-release fitting.

30. Remove the 4 throttle valve module bolts (1).
31. Remove the throttle valve module.
32. Remove the 7 intake manifold bolts (1).
33. Remove the intake manifold.
34. Remove the 2 wiring harness bracket bolts.
35. Remove the wiring harness bracket.
36. Remove the fuel rail system.