Procedures

Replacing The Intake Manifold/Gasket

Special Tools: 999 5666

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 injection system.
- These illustrations are not fully accurate because the pulsed secondary air injection system (PAIR) pump has been discontinued.

Removing







- Remove
- the control module box air baffle.
- the cover plate over the injectors.
- injector connectors.
- 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.
- Remove 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 mounting screws from the fuel rail.
- Separate the fuel line quick-release connector.
- Use tool 951 2666.

- 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 and gasket.







- Remove
- 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

NOTE: Ensure that there is no exhaust leakage.

Transfer







- The electronic throttle body (TB).
- Use a new gasket.
- Tighten to 10 Nm.

Installing The Intake Manifold And 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. The hose must be inserted 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.
- Tighten to 20 Nm.

Finishing

Install







- the fuel rail.
- Press together the quick-release connector.
- Use new screws.
- Tighten to 10 Nm.

- the connectors for the injectors and the cover plate.
- the vacuum hoses according to the earlier markings.
- 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 dip stick in the intake manifold.

Final Check

Test Drive The Car. Check The Following:
- that there is no fuel leakage.
- that the engine is operating 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.