Method E, LH/EZ Only, All Markets
REPLACING PCV / PRE-HEATING SYSTEM
NOTE: Method "A" should be performed prior to this method if the vehicle is older than M/Y 96 (production date 03/96).
Special Tools Required:
- Injector clamps (4) 999 5533
- Injector clamp (1) 999 5620
- H-cleaner 1161436-9
- Metal adhesive 1161351-0
Parts Required, All Markets
PCV-System:
- PCV-basic kit 272251-0
- Additional PCV parts see table
- Vacuum labels see table
Pre-Heating System:
- Pre-heating basic kit 272252-8
- Additional pre-heating parts (B5204S, B5254S, LH/EZ)
Air filter cover 9434292-0
Inlet hose N/A
- Vacuum labels see table
E1 Remove:
- Battery negative lead
- Throttle pulley cover
Removing Engine Coolant Fan Shroud
E2 Remove:
- Air intake scoop in front and inlet hose to the Air Cleaner (ACL)
- Air duct to the control module box
- 4 screws on engine coolant fan (FC) shroud.
E3 Remove:
- EVAP valve including hoses from engine coolant fan (FC) shroud (if applicable)
- EGR controller from upper air guide and from EGR controller connector.
E4 Remove:
- Clamp from insulation (if EVAP-valve is insulated).
- Hose from EVAP-valve.
E5 Remove:
- Disconnect and free the two connectors (A) to the engine coolant fan (FC)
- The cable from the tie straps (B) on the engine coolant fan (FC) shroud.
Place the air guide with the relays on the engine.
Remove:
- Engine coolant fan (FC), by pulling engine coolant fan (FC) and shroud upwards.
Cover the radiator with protective panel P/N 999 5474 or equivalent.
E6 Remove:
- Throttle cable from bracket and throttle pulley.
Removing Intake Manifold
E7 Remove:
- Ignition lead Cover
- Upper hose on Cylinder head.
E8 Remove:
- Fuel rail Cover
- Electrical Connectors from injectors
- Lower and Upper Clamp.
When removing the fuel rail the injectors should be fixed so that they cannot twist loose and Spray fuel.
E9 Install:
Early fuel rail:
- Five Clamps 999 5533 to the injectors.
Later fuel rail (with quick connect coupling):
- Four Clamps 999 5533 and one Clamp 999 5620 to the injector position Clam Position clamp 999 5620 Closest to the fuel pressure line as illustrated at E10 (below).
Press in the clamps so that they are in good contact with injectors.
- Screw down adjustment screw so that the contact plate is in contact with the fuel rail, turn the screw another half turn.
E10:
The Figure shows clamp 999 5620 positioned closest to the fuel pressure line (late fuel rail).
E11 Remove:
- Vacuum hose from multi nipple
- Bolts holding fuel rail
- Lift the fuel rail twisting it carefully to the side.
NOTE: Handle injectors carefully so as not to damage fuel jets and fuel needles.
E12 Remove:
- Inlet hose between Air Cleaner (ACL) and Throttle Body (TB).
- Idle Air Control Valve (IAC) hose and hose for crankcase ventilation (PCV) from inlet hose.
- Idle air valve and Throttle Position (TP) sensor connectors.
E13 Remove:
- Throttle Body (TB) link
- Throttle Body (TB) from intake manifold
- 4 bolts (they will be reused)
- Gasket between Throttle Body (TB) and intake manifold.
Ensure that no gasket residue is left on the intake manifold gasket face.
Clean Throttle Body (TB) if dirty.
NOTE: Throttle body (TB) must be removed to not damage the throttle.
E14 Remove:
- Pipe from EGR valve (tap pipe back)
- EGR temperature sensor wire from connection
- Cable harness from throttle control bracket
- Intake manifold three upper bolts
- Dipstick mounting from intake manifold
- Brake booster hose from intake manifold.
Loosen the lower intake manifold bolts.
Remove:
- Intake manifold support bracket bolt
- Intake manifold, by lifting it approx. 20 mm (1") to free it from the engine
- Intake manifold gasket.
Install:
- Plug on EGR temperature sensor connection.
Clean gasket faces on cylinder head and intake manifold.
Replacing Front Manifold Plug
NOTE: Wear protective goggles.
E15 Remove:
- Knock front plug out of intake manifold using an extension rod.
E16:
- Clean sides of hole using H-cleaner P/N 1161436-9.
Install:
- Nipple plug using a 30 mm (1 3/16") socket.
NOTE: On older cars without a stop ridge be careful so that the nipple plug does not go in too far. It should be 0.5 to 1.0 mm below the edge.
E17 When nipple plug is in place:
- Secure the nipple plug by staking the manifold with a chisel in 4 places
- Apply a bead of metal adhesive P/N 1161351-0 around the edge.
Replacing Crankcase Ventilation (PCV) Hoses And Oil Trap
E18 Remove:
- Intake manifold bracket from the engine block.
E19 Disconnect:
- All hoses from oil trap.
Discard hose (A).
Remove:
- Oil trap and discard.
NOTE: Clamp the upper hose, routed to the cylinder head, before installing the oil trap, (not applicable on all engines).
Install:
- New oil trap
- New crankcase ventilation hose (A).
E20:
When PCV-hose is installed on oil trap, mark the hose and coupling piece and pull apart.
Route the PCV-hose between the 3th and 4th pipe on the intake manifold.
Remove the flametrap and discard.
E21 Install:
- Intake manifold bracket on engine block (finger tight).
Install The Intake Manifold
E22 Install:
- New gasket and enter the four lower bolts.
E23 Install:
- Crankcase ventilation (small) hose on nipple plug
- Hose to the cylinder head, between manifold pipe 2 and 3 (not applicable on all engines).
E24 Install:
- Intake manifold
- Dipstick mounting on intake manifold
- EGR valve pipe and EGR temperature sensor wire connector (not Motronic 4.3)
- Intake manifold three upper bolts.
Tighten all seven bolts to 17 Nm (12 ft. lbs).
Install:
- Intake manifold support bracket bolt and tighten both bolts
- Brake booster hose to intake manifold.
Install Throttle Body (TB)
E25 Install:
- Throttle Body (TB) gasket.
E26 Install:
- Throttle Body (TB).
Re-use the four bolts, torque 10 Nm (7.5 ft. lbs).
E27 Adjust Link:
- Undo link locknut.
Check that the link can be pulled out and that it springs back when released.
E28 Install:
- link between throttle pulley and throttle spindle.
Check:
- That throttle spindle is in contact with adjustment screw.
- That throttle pulley is in contact with idling stop.
Tighten link locknut.
Open and close throttle.
Check:
- That the throttle spindle is in contact with adjustment screw.
Replacing Air Cleaner (ACL) Housing
The new Air Cleaner (ACL) housing has vacuum controlled air pre-heating.
E29 Remove:
- Air Cleaner (ACL) housing with pre-heating hose and discard.
Move Mass Air Flow (MAF) sensor to new Air Cleaner (ACL) cover.
Move old filter to air cleaner (ACL) filter housing.
Clean filter if necessary.
Preparation:
- Assemble the Air Cleaner (ACL) housing (filter, cover, filter housing).
- Connect the black hose to the upper (metallic) nipple on the Air Cleaner (ACL) cover.
Install:
- New white vacuum hose to lower (plastic) nipple on Air Cleaner (ACL) cover. Use elbow connection.
- Tie the two vacuum hoses together to prevent white hose rubbing on ABS bracket.
Position the tie 50 mm (2") from the elbow connection.
E30 Install:
- Protective sleeve (150 mm, 6") on the Mass Air Flow (MAF) sensor wire.
Position the protective sleeve on the cable channel.
E31 Install:
- Fuel rail.
- Bolts holding fuel rail.
IMPORTANT: Tightening torque 10 Nm (7.5 ft. lbs). Use new screws.
Install:
- Vacuum hose to lower rear fitting of multi nipple.
NOTE: Handle injectors carefully not to damage fuel injectors. Check the injector seals are in place.
E32 Remove:
- Injector clamps.
Install:
- Clamps holding fuel rail.
- Connectors on injectors.
- Fuel rail cover.
E33 Install:
- New Air Cleaner (ACL) housing
- New pre-heating hose at exhaust manifold.
The new pre-heating hose should be 100 mm (4") longer than the old one, adjust if necessary (by cutting).
Connect mass air flow (MAF) harness.
Install:
- Coil high tension lead on Air Cleaner (ACL) housing.
- The white vacuum hose from Air Cleaner (ACL) to upper rear multi nipple outlet.
E34 Install:
- Clamp vacuum hose with injector wire to throttle pulley bracket, using provided bigger clamp.
IMPORTANT: Position vacuum hose to the rear of injector harness in clamp.
Make sure vacuum hose is not squeezed in clamp.
NOTE: Check that all nipples at multi nipple either has a hose connected or has a plug.
Install:
- Protective insulation hose on the PCV pipe.
Re-assemble the flame trap and PCV pipe according to earlier performed marking (E20).
Installing Parts
E36 Install:
- Re-Install O-ring on flame trap.
- The new crankcase ventilation hose to the new (if applicable) inlet hose.
- New (if applicable) inlet hose between Air Cleaner (ACL) and Throttle Body (TB).
- Idle Air Valve (CIS) hose.
E37:
- Clean crankcase ventilation (PCV) hose and nipple at the cylinder head connection.
Install:
- Upper crankcase ventilation (PCV) hose on the cylinder head
- Ignition lead cover.
E38 Install:
- Throttle cable on throttle pulley and bracket.
E39 Remove:
- Protective panel from the radiator.
Install:
- Engine coolant fan (FC) and shroud.
- The two lower engine coolant fan (FC) screws.
Fix the cable with the tie strap and clip.
Connect two connector to engine coolant fan (FC).
E40 Install:
- EVAP hose with clips to the coolant fan (FC).
- EVAP valve with two screws.
- EGR controller valve on upper air guide (not Motronic 4.3).
E41 Install:
- Hose to EVAP-valve.
- Clamp insulation with strip clamp.
E42 Install:
- Two spacer washers on top.
- Upper air guide.
- Two upper engine coolant fan (FC) screws and tighten all four.
- Air intake and inlet hose to the Air Cleaner (ACL).
- Throttle pulley cover.
E43 Install:
- Plug and clip as shown and park the EGR controller connector in the plug.
E44 Install:
- Battery negative lead.
- Reset radio anti-theft code.
Perform Test Drive
- Check that there are no DTC's stored in the system after the test drive.