Intake Manifold: Service and Repair

INTAKE MANIFOLD

REMOVAL

WARNING: NO FIRE, SPARKS OR SMOKING. STORE FUELS ONLY INTO SUITABLE AND APPROPRIATELY MARKED CONTAINERS, AND WEAR PROTECTIVE CLOTHING. (Refer to FUEL SYSTEM WARNING).

WARNING: DO NOT OPEN THE COOLING SYSTEM UNLESS THE COOLANT TEMPERATURE IS BELOW 90°C (194°F). OPEN RADIATOR CAP SLOWLY TO RELEASE PRESSURE. STORE COOLANT ONLY INTO SUITABLE AND APPROPRIATELY MARKED CONTAINERS, WEAR PROTECTIVE CLOTHING AND EYE PROTECTION.


1. Disconnect the negative battery cable.
2. Partially drain coolant from the radiator.
3. Remove the engine cover.





4. Remove the high pressure fuel lines (Fig. 66).
5. Remove the fuel rail.
6. Remove the fuel rail support block between cylinders #1 and #2 (Fig. 66).





7. Disconnect the charge air hose at the intake manifold (Fig. 67).
8. Disconnect the EGR wiring harness connector (Fig. 67).
9. Remove the bolt retaining the engine wiring harness to the intake manifold.
10. Disconnect the coolant hose at the EGR valve.

NOTE: Collect and store any fluid spillage when disconnecting components.

11. Disconnect both fuel lines at the fuel filter (Fig. 67).





12. Remove the lower intake manifold support bracket (Fig. 68).
13. Raise and support the vehicle.
14. Remove the rear intake manifold mounting bolts while accessible from below.
15. Lower the vehicle.

NOTE: Access to one of the intake manifold bolts is through a supplied hole in the manifold.

16. Remove the remaining intake manifold bolts, lift the intake manifold up and out while guiding the engine wiring harness and fuel lines through the openings in the intake manifold, then remove the gasket (Fig. 68).

NOTE: Install the EGR valve with new gasket onto the new intake manifold if the intake manifold is being replaced.

INSTALLATION

NOTE: If the intake manifold is being replaced, install the EGR valve with new gasket.

1. Clean both mating surfaces and install a new intake manifold gasket with the intake manifold. Guide the engine wiring harness and fuel lines through the intake manifold openings. Tighten manifold bolts to 16 Nm (142 inch lbs.) in a cross directional pattern beginning with the middle bolts and tightening outward to the ends.
2. Raise and support the vehicle.
3. Install the rear intake manifold bolts and tighten to 16 Nm (142 inch lbs.) (Fig. 68).
4. Install the lower intake manifold support bracket. Tighten bolts to 20 Nm (177 inch lbs.) (Fig. 68).
5. Lower the vehicle.
6. Connect both fuel lines to fuel filter assembly.
7. Connect the coolant hose at the EGR valve (Fig. 67).
8. Secure the engine wiring harness and cable duct to the intake manifold. tighten fastener to 9 Nm (80 inch lbs.).
9. Connect the EGR wiring harness connector (Fig. 67).
10. Connect the fuel pressure sensor electrical connector
11. Install the fuel rail.

NOTE: The high pressure fuel lines must be counter held when tightening to prevent damage.

12. Install the high pressure fuel lines.
13. Connect the charge air hose to the intake manifold (Fig. 67).
14. Install the engine cover.
15. Fill the cooling system.
16. Connect the negative battery cable.
17. Start the engine, run until warm, turn engine off and inspect for leaks. Care must be taken to observe the fuel system warning.