Intake Manifold: Service and Repair

Intake manifold, removing and installing

Removing:

Note:
All cable ties which are released or cut open when removing must be installed in the same position when installing.

- Obtain radio anti-theft code on vehicles with coded radio.
- With ignition switched off disconnect battery Ground (GND) strap.
- Remove engine cover.





- Disconnect connector -3- for Intake Air Temperature (IAT) sensor -G42- and connector -4- for throttle valve control module -J338 (below throttle valve control module).
- Disconnect air hose -2- from throttle valve control module.
- Disconnect vacuum hose -1- from throttle valve control module (hose leads to activated charcoal filter).





- Remove intake air duct -arrows-.





- Pull connector off Camshaft Position (CMP) Sensor -G40- (arrow).





- Disconnect connectors -1- for injectors and unclip support bar from fuel rail -2-.





- Disconnect connector -1- for electrical change-over valve on underside of bracket.
- Unbolt bracket from intake manifold (-2- and -3-) and disengage dipstick tube -4-.





- Press release tabs and pull fuel supply line -1- and fuel return line -2- off connections.

WARNING!
Fuel system is under pressure! Before opening the system place a cloth around the connection. Then release pressure by carefully loosening the connection.

- Disconnect crankcase breather hose from T-piece.
- Unbolt intake manifold support from intake manifold.
- Pull out oil dipstick.
- Unbolt intake manifold at flange and remove.

Installing:

Installation is carried out in the reverse order, when doing this note the following:

- After connecting battery terminals, enter anti-theft code for radio
- Close electric windows in front doors all the way to their top positions using electric switches.
- Then operate all electric window switches again for at least one second in the "close" direction to activate the automatic one-touch function.
- Set clock to correct time.
- Perform adaption of throttle valve control module

- Interrogate DTC memory

Note:
DTCs will have been stored in the memory because connectors have been disconnected. Therefore interrogate and erase DTC memory after installing engine.