Removal and Replacement

Intake manifold/gasket, replacing

Special tools:
999 5666 Wrench 999 5666 Wrench

Replacement of intake manifold/gasket

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

Preparation




Drain the fuel system. See Fuel system pressure release Fuel System Pressure Release.




Method is the same for both aspiration and turbo engines.
The engine compartment figures show a turbo engine.
These figures are not exactly correct since the air pump has been discontinued.

Remove
- the control module box air baffle.
- cover plate over the injectors.
- the connectors from the injectors.
- connectors for the sensors in plastic charge-air pipe between charge-air cooler and throttle module.
- the cover over the ignition coils
Part the connector for the electronic throttle body.
Part the charge-air pipe at hose/plastic pipe.
Remove the plastic charge-air pipe.
Seal the opening.
Mark up and remove the vacuum hoses from the intake pipe.
- the cover over the ignition coils
Remove the hose from the oil trap for the cam cover at the connection in the cam cover.




Remove the mounting screws from the fuel rail.
Part the fuel line's quick-coupling.
Use tool 951 2666 Replaced by 9997298 951 2666 Wrench (Replaced by 9997298).
Spray universal oil or similar around the injector nozzle at the connection on the intake pipe.
Gently work the fuel rail and injector nozzles loose




Removing the intake manifold and gasket

Remove
- oil dipstick's bracket.
- the lower screws for the intake manifold a few turns.

Remove
- the mounting screws in the upper row and the outer 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

Note! For tightening torques, see: Tightening torque, B5234T9 Tightening Torque.

Note! To ensure that there is no exhaust leakage, see: Flanged joint, assembling Service and Repair.





Transfer
- The electronic throttle body
Use a new gasket .
Tighten to 10 Nm .

Installing the intake manifold and gasket





Note! Make sure that the gasket faces are clean.

Install
- a new gasket . The gasket is held in place by the lower screws for the intake manifold.
- the intake manifold.
Do not forget the hose for the crankcase ventilation which should be routed up through the gap between the second and third channel
- place the pressure pipe between the first and second channel.
- the three upper screws.
Tighten all screws starting from the middle.
with 20 Nm .

Finishing





Install
- the fuel distribution pipe.
Press together the quick-coupling.
Use new screws .
Tighten to 10 Nm .
- connectors for the injector valves and the cover plate.
- the vacuum hoses according to the earlier markings
- the plastic charge-air pipe and the hose for the charge-air cooler.
- connectors for sensors in the plastic charge-air pipe.
- air baffle from the control module box at the electric cooling fan shroud.
- the dip stick in the intake manifold.

Final check

Test drive the car. Check the following:
- that there is no fuel leakage
- that the engine operates normally.
- that no diagnostic trouble codes are stored.
Check that everything is in position. Clean the engine compartment.
Wipe clean steering wheel and gear lever.