Removing Intake Manifold

Remove:

- Intake manifold upper bolts (3).

- Dipstick and bracket from intake manifold.

- Intake manifold lower bolts.

- Gas recirculation pipe from EGR valve.

- Intake manifold support bracket bolt.

- Intake manifold, by lifting it approx. 20 mm (3/4") to free it from the engine.

- Crankcase ventilation hose from intake manifold at servo pump (if equipped).

- Intake manifold gasket.

Clean gasket faces on cylinder head and intake manifold.

Remove:

- Starter motor bracket

Remove

- Knock sensor (KS) connectors

- Knock sensors (KS)

Replace cable terminals and receptacle housings

Replace cable terminals and receptacle housings on cables from engine compartment cable harness to knock sensors (KS).

See Service Manual "Wiring repairs and replacement of cable terminals" 850, 900 sections DD, EB, FA, FB, GB, GC, GD, J.

Note:
Ground cables (two-tone) should be connected to position 2 in the receptacle housing.

Pull the shorter cable (to the rear knock sensor (KS)) out of the protective sleeve so that it reaches the engine wiring duct.

Note:
The knock sensor (KS) cable should be routed under the starter motor/starter motor bracket.

Tape the ends of the protective sleeve where the rear knock sensor (KS) wiring emerges.

Install protective sleeve on wiring.

Cut to the correct length. Protective sleeve is available by the meter.

Install bracket, adapter wiring and clip as illustrated.

Install knock sensors (KS) and tighten to 20 Nm (15 ft. lbs).

Note:
Tighten front knock sensor (KS) in the three o'clock position and rear knock sensor (KS) in the five o'clock position.

Install bracket with adapter wiring on the engine wiring duct.

Route the cable from the knock sensors (KS) and the two existing cables under the starter motor bracket to the cable duct.

Note:
Check the cable color markings so that they are connected to the correct connector on the adapter wiring.

Clamp the connectors and wiring to the cable duct with two tie straps as illustrated.