Intake Manifold: Service and Repair

Intake manifold, removing and installing

Removing

Notes: All cable ties, which are released or cut open when removing must be fitted in the same position when installing.

- Obtain radio code on vehicles with coded radio.
- With ignition switched off, disconnect battery Ground strap.
- Remove engine cover.




- Unplug connector -1- for intake air temperature sender - G42 and connector -4- for throttle valve control part - J338 (located under throttle valve control part).
- Disconnect air hose -2- from throttle valve control part.
- Disconnect vacuum hose -3- from throttle valve control part (hose leads to activated charcoal filter).




- Disconnect connector off Hall sender - G40 -arrow-.




- Disconnect connectors -1- for injectors and unclip support bar from fuel rail -2-.




- Disconnect connector -1- for electrical change - over valve on underside of bracket.
- Unbolt bracket from intake manifold (-2- and -3-) and disengage dipstick tube -4-




- Press release tabs and pull fuel supply line -1- and fuel return line - 2 - off connections.

WARNING! Fuel system is under pressure! Before opening the system place a cloth around the connection. Then release pressure by carefully loosening the connection.

- Disconnect crankcase breather hose from T-piece.
- Unbolt intake manifold support from intake manifold.
- Pull out oil dipstick.
- Unbolt intake manifold at flange and remove.


Installing
Installation is carried out in the reverse order of removal:
- After connecting battery terminals, enter anti-theft code for radio.
Refer to Radio operating instructions
- Close electric windows in front doors all the way to their top positions using electric switches.
- Operate all electric window switches again for at least one second in the "close" direction to activate the automatic one - touch function.
- Set clock to correct time.
- Perform adaptation of throttle valve control part.
- Check DTC memory.

Note: DTCs will be stored in the memory because connectors have been unplugged. Therefore, check and erase DTC memory after installing the engine.