Intake Manifold: Service and Repair

Intake pipe/gasket, replacement

Special tools:
951 2666 Replaced by 9997298 951 2666 Wrench (Replaced by 9997298)

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 in the illustrations is always correct.

Preparation
Drain the fuel line. See Fuel system pressure release Fuel System Pressure Release.





Only applies when removing and installing the intake manifold
Remove the vacuum hoses from the upper intake manifold.
Disconnect the connector for the electronic throttle module.
Slacken off the hose clamp for the inlet hose at the air cleaner (ACL) housing.

Removing the intake manifold, upper section





Remove:
- the screw in the mating flange of the intake manifold
- the crankcase ventilation hose from the underneath of the upper section of the intake manifold.

When removing and installing the intake manifold:
Lift off the upper section of the intake manifold.

When replacing the gasket:
Turn the upper half of the intake manifold to one side.
Remove the gasket.

Hint: Cover the gasket face on the lower half of the intake manifold to prevent dirt getting in. Use broad tape.

Removing the fuel rail




Separate the quick-release fuel line connector. See Fuel line, lock Service and Repair.
Use tool 951 2666 Replaced by 9997298 951 2666 Wrench (Replaced by 9997298).

Remove:
- the screw securing the mounting for the dip stick pipe to the intake manifold
- the connectors for the injectors
- the screws for the fuel rail.
Spray universal oil or similar around the injector terminals on the intake manifold.
Gently work the fuel rail and injectors loose.
Put the fuel rail to one side.

Note! Handle the injector valves carefully to avoid damaging the injector valves' nozzles with needles.

Removing the intake manifold, lower section

Remove:
- the upper screws
- the outer screws from the lower row.
Slacken off the remaining screws.
Lift up and remove the lower section of the intake manifold.

Replacing gasket




Remove the remaining screws and gasket.
Clean the gasket face.
Install new gasket with the two center screws in the lower row.

Transferring components when replacing the intake manifold

Transfer
- throttle module (ETM). Use new gasket. Tighten with 10 Nm

Installing the intake manifold, lower section
Lower the intake manifold onto the three screws.
Install the remaining screws.
Tighten all the screws with 20 Nm.

Installing the fuel rail





Install
- the fuel rail using new screws. Tighten to 10 Nm
- the fuel line quick-release connector. See Fuel line, lock Service and Repair. Use lubricant 116 1580.

Note! Check that the connector is installed correctly.

- The injector connectors.

Installing the intake manifold, upper section





Install:
- a new gasket
- the crankcase ventilation hose
- the intake manifold and install all screws. Tighten to 17 Nm.

Finishing





When replacing the intake manifold:
Connect the connector for the electronic throttle module.

Install:
- the vacuum hoses according to the earlier markings
- the screw securing the mounting for the dip stick pipe to the intake manifold
- the inlet hose between the air cleaner (ACL) housing and throttle body (TB).
Test drive the engine.