Intake Air Plenum: Service and Repair

Induction pipe

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. See: Fuel system pressure release Fuel System Pressure Release.
Remove the air cleaner (ACL) module. See: Air filter module Service and Repair.

Removal

Removing the 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
- canister hose from the intake manifold
- the brake vacuum pipe, by pressing in the red catch and pulling out the pipe.

Disconnect the connector for:
- the throttle body
- the pressure sensor on the induction pipe. Cut off the cable ties for the cable harness for the pressure sensor. Place the intake manifold to one side.

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





Remove:
- the fuel rail mounting screws.
- screw for the clamp for the fuel pressure pipe.
Blow the clean the injectors. Spray using universal oil or similar around the terminals of the injectors 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:
- screws on the top row to the intake pipes. Loosen the screws on the lower row a few turns. Lift up the intake manifold and loosen the hose between the oil trap and the intake manifold.
- gasket and discard it.

Installation

Note! For tightening torques, see Specifications. Tightening Torque

Installing the intake manifold and gasket





Note! Ensure that the gasket faces are clean.

Install:
- a new gasket. The gasket is held in place 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
- screws for the top row. Tighten according to: Tightening torque Tightening Torque.

Installing the fuel rail




Lubricate the injector O-rings with lubricant 116 1580. Press the fuel rail down. Ensure that all injectors locate correctly. 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 to the positive crankcase ventilation and squeeze 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. Tighten according to: Tightening torque Tightening Torque
- the canister hose
- brake vacuum hose.

Connect the connector to:
- the pressure sensor on the intake manifold and install a new cable tie on the wiring harness
- the mass air flow sensor.

Finishing

Installing the air cleaner (ACL) module
Install the air cleaner (ACL) module. See: Air filter module Service and Repair.

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