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

Removing upper intake manifold

Remove:







- the 6 screws for the upper intake manifold, closest to the front cover plate, and the 2 screws against the firewall
- the EVAP canister hose from the intake manifold
- the brake vacuum pipe. Press in the red catch. Pull out the pipe.

Disconnect the connector for:
- throttle body (TB)
- the pressure sensor on the intake manifold. Cut the tie strap for the pressure sensor cable harness. Put the intake manifold to one side.

Removing the injectors
Disconnect the connector for the injectors and the fuel pressure sensor in the fuel rail.

Remove:







- the fuel rail mounting screws
- the screw for the fuel pressure pipe clamp.

Blow clean around the injectors. Spray universal oil or similar around the injector terminals on the intake manifold.

Pull out the fuel rail and injectors. Do not work them loose from side to side. Separate the fuel line quick-release connector. Press the two blue plastic buttons. Lift out the fuel rail.

Removing the lower intake manifold

Remove:







- the screws in the upper row for the intake manifold. Slacken off the screws in the lower row a few turns. Lift up the intake manifold. Detach the hose between the oil trap and the intake manifold
- the gasket. Discard the gasket.

Installation

NOTE: For tightening torques, see Specifications.

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

NOTE: Route the crankcase ventilation hose up between cylinders 2 and 3.

- the hose between the oil trap and the intake manifold
- the screws for the upper row.

Installing the fuel rail







Lubricate the injector O-rings using lubricant 116 1580. Press down the fuel rail. Ensure that the injectors are correctly positioned. Press the quick release connector together until a clicking sound is heard.

Tighten the screws for the fuel rail. Tighten the clamp for the fuel pressure pipe. Connect all the connectors to the injectors and to the fuel pressure sensor. Install a new clamp for the crankcase ventilation hose and clamp together.

Installing upper intake manifold

CAUTION: Ensure that the guides for the lower section are in the correct position.

Install:







- new gaskets for the upper section of the intake manifold
- the upper intake manifold.
- the EVAP canister hose
- the brake vacuum hose.

Connect the connector for:
- the pressure sensor on the intake manifold. Install a new tie strap for the cable harness
- the mass air flow (MAF) sensor.

Finishing

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

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