Intake Manifold/Gasket, Replacing

Intake Manifold/Gasket, Replacing

NOTE: 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.

Preparatory work

Removing components
Drain the fuel system.
Remove the air cleaner (ACL) module.

Remove:
- the hose clamp for the rubber hose on the throttle body (TB). Move the hose to one side. Disconnect the throttle body (TB) connector
- the brake vacuum hose on the intake manifold.

Removal

Removing upper intake manifold







Remove the 6 screws for the upper section of the intake manifold. Disconnect the vacuum hoses from the intake manifold. Put the pipe to one side.

Removing the fuel rail

CAUTION: Clean up any spilled fuel using paper.







Disconnect the connectors for the fuel pressure sensor and the connector for the injectors. Remove the 2 fuel rail mounting screws. 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. Disconnect the fuel line to the fuel rail. Press in the two blue clips on the fuel rail. Pull the fuel line out of the fuel rail. Place the fuel rail to one side.

Removing components

Remove:







- the intake manifold on the turbocharger (TC) and seal openings
- the cover over the ignition coils.

Removing intake manifold

Remove:







- the hose from the oil trap to the timing belt cover at the terminal in the timing belt cover
- the crankcase ventilation hoses from the intake manifold
- the clamp for the fuel intake manifold
- the lower screws for the intake manifold a few turns
- the mounting screws in the upper row. Lift out the intake manifold
- the screws in the lower row
- the gasket for the intake manifold.

Installation

NOTE: For tightening torques, see Specifications.

Installing intake manifold

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
- the three upper screws. Tighten all the screws starting from the center.
- the clamp for the fuel line on the intake manifold.

Installing components

Install:
- the crankcase ventilation hoses on the intake manifold
- the hose from the oil trap to the camshaft cover. Use a new hose clamp.

Installing the fuel rail







Lubricate the injector O-rings using petroleum jelly. Depress the fuel rail. Ensure that all injectors sit correctly.

Press the quick-release connector together until clicking sound is heard. Screw the fuel rail into place. Connect the connector for the injectors and the fuel pressure sensors.

Transferring components when replacing the upper intake manifold
Transfer the electronic throttle module. Use a new gasket.

Installing upper intake manifold

Install:







- new gaskets for the intake manifold vacuum hoses for the intake manifold
- the intake manifold. Align the guides with the lower section of the intake manifold
- the screws for the intake manifold.

Finishing

Installing components

Install:







- the brake vacuum hose
- the hose for the throttle body (TB). Tighten the hose clamp
- the cover over the ignition coils. Tighten the screws
- the intake manifold for the turbocharger (TC). Remove the seals.

Installing the air cleaner (ACL) module
Install the air cleaner (ACL) module.

Checks
Start the engine. Check the function of the engine. Check for leakage.