Intake Pipe/Gasket, Replacement

Intake pipe/gasket, replacement

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 is always correct.

Replacing intake pipe and gasket

Removing the intake manifold and gasket
Remove the battery's minus cable. First read Battery, disconnecting Battery Disconnecting.




Drain the fuel system. See Fuel system pressure release Service and Repair.

Remove
- the control module box air baffle.
- the cover plate over the connectors from the injectors.
- connectors for the sensors in charge-air pipe between charge-air cooler and throttle module
Separate the throttle body (TB) connector.
Part the charge-air pipe at hose/plastic pipe.
Remove the plastic charge-air pipe.
Seal the openings.
Mark up and remove the vacuum hoses from the intake pipe.
Remove the oil filler cap.
Remove 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.
Open the fuel line's quick-release connector using tool 951 2666 Replaced by 9997298 951 2666 Wrench (Replaced by 9997298).
Spray universal oil or similar around the injector at the connection on the intake pipe.
Gently work the fuel rail and injector nozzles loose





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




- Transfer the electronic throttle module.
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 held in position by the lower screws for the intake manifold. Do not forget the clamp for the fuel line at the screw in the lower row.
- 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
- the three upper screws. Tighten all the screws starting from the middle with 20 Nm.

Finishing





Install
- the fuel distribution pipe.
Press together the quick-coupling. Use new screws. Tighten with 10 Nm.
- connectors for the injector valves and the cover plate.
- the vacuum hoses according to the earlier markings
- plastic charge-air pipe.
- connectors for sensors in the plastic charge-air pipe.
- connectors for the throttle body.
- 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.
Check that everything is in position. Clean the engine compartment.