Procedures

Special Tools
999 5666

Replacing the intake manifold/gasket

Note! As the illustrations in the information are used for different model years and/or models, certain variations may occur. However, the essential information in the illustrations is always correct.

Preparation





Drain the fuel system according to Draining the fuel system, refer to Powertrain Management.





The method is the same for both naturally aspirated and turbocharged engines.
The engine compartment illustrations show a turbocharged engine.
These illustrations are not accurate because the Pulsed Secondary Air Injection System (PAIR) pump has been discontinued.

Remove
- the control module box air baffle.
- the cover plate over the injectors.
- the connectors from the injectors.
- the connectors for the sensors in the plastic charge air pipe between the Charge Air Cooler (CAC) and the Throttle Body (TB).
- the cover over the ignition coils.

Separate the connector for the electronic Throttle Body (TB).
Separate the charge air pipe at the hose/plastic pipe.
Remove the plastic charge air pipe.
Seal the opening.
Mark up and remove the vacuum hoses from the intake manifold.
- the cover over the ignition coils.

Remove the hose from the flame trap to the cam cover at the terminal in the cam cover.





Remove the fuel rail mounting screws.
Separate the fuel line quick-release connector.
Use tool 9512666.
Spray universal oil or similar around the injector nozzle at the terminal on the intake manifold.
Gently work the fuel rail and injector nozzles loose.

Removing the intake manifold/gasket
Slacken off
- the dipstick bracket.





- the lower screws for the intake manifold a few turns.

Remove
- the mounting screws in the upper row and the outer screws in the lower row.
- the intake manifold by lifting it approximately 20 mm. Allow the crankcase ventilation hose to run through the intake manifold without disconnecting it from the flame trap.

Transferring components when replacing the intake manifold
Transfer





- The electronic Throttle Body (TB). Use a new gasket. Tighten to 1O Nm (7.4 ft. lbs.).

Installing the intake manifold/gasket

Note! Ensure that the gasket faces are clean.

Install
- a new gasket held in position by the lower screws for the intake manifold.





- the intake manifold. Do not forget the crankcase ventilation hose which comes up through the gap between the second and third ducts.
- position the delivery line between the first and second duct.
- the three upper screws. Tighten all screws starting from the center. to 20 Nm (15 ft. lbs.).

Finishing
Install





- the fuel rail. Press together the quick-release connector. Use new screws. Tighten to 1O Nm (7.4 ft. lbs.).
- the connectors for the injectors and the cover plate.
- the vacuum hoses according to earlier marking.
- the plastic charge air pipe and the hose to the Charge Air Cooler (CAC).
- the connectors for the sensors in the plastic charge air pipe.
- the air baffle from the control module box at the engine Cooling Fan (FC).
- the dipstick in the intake manifold.

Final check
Test drive car and check the following:
- that there is no fuel leakage.
- that the engine operates normally.
- that no Diagnostic Trouble Codes (DTCs) are stored.

Check that everything is in position. Clean the engine compartment.
Wipe the steering wheel and gear selector lever clean.