Procedures

Special Tools
999 5533

Note! The intake manifold is stocked complete with Throttle Body (TB) and damper spindles for engines with damper spindles

Replacing intake manifold
See also Intake Manifold Gasket, Service and Repair for replacement
Disconnect fuel rail with the injectors.





Remove throttle pulley and injector cover. Remove throttle cable.
Disconnect connectors and mountings from injectors.
Remove the two fuel line brackets and two fuel rail mounting screws.
Install the five holders 999 5533. Carefully pull up the injectors with the fuel rail.
Disconnect hose from Canister Purge (CP) valve.
Carefully place fuel rail with injectors on engine.

Caution: Injector nozzles with fuel needles must not be damaged.

Remove





- throttle linkage from pulley
- intake air hose to the throttle body
- multi-nipple
- throttle pulley with bracket and idle speed control valve
- Throttle Body (TB)
- clamp for EGR hose (Turbocharger (TC)).
- pressure hose to Turbocharger (TC) instruments/EGR valve control vacuum hose
- brake servo hoses

Remove
- dipstick bracket





- intake manifold screw in lower bracket
- lower intake manifold screws a few turns.

Remove
- remove three upper intake manifold screws
- intake manifold by lifting it approximately 20 mm. (Allow the crankcase ventilation hose run through the intake manifold without disconnecting it from the flame trap, does not apply to Turbocharger (TC)models.

Install
- a new gasket held in position by the lower intake manifold screws. Do not forget the clamp on the fourth socket turbocharged engines.)





- intake manifold. (Do not forget the crankcase ventilation hose which comes up through the gap on the 2nd and 3rd ducts on the S engines.)
- the three upper screws and tighten all the screws from the middle to 20 Nm.

Install

Part 1 Of 2:

- EGR valve with new gasket if necessary
- throttle body with new gasket
- throttle pulley with bracket
- multi-nipple and connect hoses
- fuel rail and two brackets
- injectors wiring and cover the bracket screw under the intake manifold
- dip stick bracket screw
- brake servo hoses
- air intake hoses
- Idle Air Control (IAC) valve
- throttle linkage and throttle cable

Part 2 Of 2:

- throttle pulley cover