Intake Manifold: Service and Repair

Intake manifold, removing and installing

Removing

Note: All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.

- Drain coolant.

WARNING: For vehicles with telematic, activate service -mode of telematic- of the control module before disconnecting the battery.

- Note radio code and determine if necessary (for vehicles with coded anti-theft radio / radio-navigation system -RNS-.
- Switch ignition off and disconnect battery Ground (GND) strap.





- Remove rear engine cover (arrows).





- Remove front engine cover (arrows).





- Remove cover-1- in engine compartment (right side).





- Remove bolts (arrows).
- Remove air guide -1-.





- Detach Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80-1- at air filter housing.
- Disconnect electrical harness connector -2- at Mass Air Flow (MAP) sensor.
- Remove air guide hose -3- together with Mass Air Flow (MAF) sensor.
- Remove air filter housing (arrows).





- Disconnect vacuum hoses -2- and -3 at intake manifold change-over valve -N156-.
- Disconnect vacuum hose -6- from check valve.
- Disconnect electrical harness connector -5-.
- Move hose of crankshaft housing ventilation free (arrow).
- Remove bolts -1- , -4- and -7- for holding plate for solenoid valves.
- Remove holding plate for solenoid valves.





- Disconnect electrical harness connector -1-.
- Disconnect vacuum hose -2- from T piece.
- Remove all harness connectors to injectors.





- Disconnect vacuum line at fuel pressure regulator and remove mounting bolts of fuel pressure regulator (arrows).
- Remove fuel distributor together with fuel injectors from intake manifold simultaneously upward and place it on a clean rag in engine compartment.

Note: Carefully protect removed fuel injectors from contamination.





- Disconnect electrical harness connector -1 at throttle valve control module -J338-.
- Disconnect vacuum hoses -2- and -3-.





- Disconnect hose -1- from air guide.
- Remove bolt -4- and disconnect air guide -2- at throttle valve control module.
- If installed, disconnect vacuum hose -3- from air guide at bottom.





- Disconnect vacuum line (arrow) to leak detection pump at throttle valve control module,





- Remove bolts -1- and -3-.
- Pull out guide tube for oil dipstick -2 toward top from the oil pan (upper part) and swing it forward.

Note: Hose 4 remains connected.





- Remove bolts at right side of engine (arrows) at line for secondary air injection.





- Remove bolts -1- and -2- at lines of secondary air injection.
- Unscrew bolts -3- and -5- and remove resonator -4-.





- Disconnect vacuum hose -1- from EVAP valve.
- Disconnect coolant hoses -2- and -3-.





- Unbolt intake manifold (arrows) and remove.

Note: Plug intake channels in the cylinder heads with clean rags.

Installing
Installation is reverse of removal, noting the following:

Notes:
^ Secure all hose connections using hose clamps appropriate for the model type:
Refer to Parts Supplier
^ Always replace seals and gaskets.





- Bolt in intake manifold in diagonal sequence in stages (arrows).
- Replace O-ring at guide tube for oil dipstick and insert guide tube into hole in oil pan (upper part).

Notes:
^ Be sure to activate vehicle features (radio/radio-navigation system, clock, electric window regulators) according to owner's manual when the battery is reconnected.
^ Deactivate service mode of telematic control module.

- Top up coolant.

Component Tightening Torques (Part 4 Of 17):

Component Tightening Torques (Part 5 Of 17):

Tightening torques