Intake Manifold: Service and Repair

Intake pipe/gasket, replacement

Removal

Note! Since 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.

Removing the intake manifold and gasket
Disconnect the battery negative lead. First read Battery, disconnecting Battery Disconnecting.




Depressurize the fuel system according to: Fuel system pressure release Fuel System Pressure Release.

Remove:
- the charge air pipe over the engine
- the cover plate over the connectors from the injectors
- the 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. Separate the fuel line quick-release connector. See: Fuel line, lock Service and Repair.
- Separate the throttle body (TB) connector
- Remove the plastic charge air pipe between the throttle body (TB) and the charge air cooler (CAC)
- Seal the openings. Mark up and remove the vacuum hoses from the intake manifold.

Remove:
- the oil filler cap
- the cover over the ignition coils
- the hose from the flame trap to the cam cover at the terminal in the cam cover.




- Disconnect the dip stick pipe
- Slacken off 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
- Remove the intake manifold by lifting it approximately 20 mm
- Remove the nipple for the water heated crankcase ventilation.
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.

Installation

Installing the intake manifold and gasket

Note! For tightening torques, see Specifications Tightening Torque.

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 nipple for the water heated crankcase ventilation
- 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 3 upper screws. Torque tighten all the screws starting from the center.

Finishing

Install
- the fuel rail. Press together the quick-release connector. Use new screws, see also: Fuel line, lock Service and Repair
- injector connectors
- the protective cover over the fuel rail
- the vacuum hoses according to the earlier markings
- the plastic charge air pipe between the throttle body (TB) and the charge air cooler (CAC)
- the connectors to the throttle body (TB)
- 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.