Intake Manifold: Service and Repair

Intake Manifold, Removing And Installing







NOTE: The procedure is described for vehicles with manual transmission. On vehicles with automatic transmission remove also the secondary air injection pump.


- Remove air distributor.


1 - Detach Wastegate Bypass Regulator Valve -N75 from fuel rail.
2 - Disconnect harness connector from EVAP Canister Purge Regulator Valve - N80.
3 - Loosen both exhaust temperature sensors -G235 and -G236 from intake manifold. The sensors remain connected. Ensure Ground cable is tight when installing.
4 - Loosen hose to brake booster at bulkhead.
5 - Disconnect harness connector from Recirculating valve for turbocharger - N249.
6 - Loosen indicated hose. The hose leads to a vacuum reservoir.
7 - Disconnect harness connectors of fuel injectors from cylinder bank 1 and bank 2.
8 - Loosen indicated hose. This hose leads to the suction side of turbocharger bank 2.
9 - Disconnect harness connector at Throttle Valve Control Module -J338.
10 - Disconnect harness connector at Charge Air Pressure Sensor -G31.
11 - Remove indicated pressure hoses
12 - Loosen indicated hose, this hose leads to bypass valve.
13 - Disconnect harness connector at Intake Air Temperature (IAT) Sensor -G42.
14 - Loosen indicated hose, (crankcase ventilation hose).
15 - Loosen indicated hose. This hose leads to the suction side of turbocharger bank 1.


WARNING!
Fire hazard! DO NOT smoke or work near heaters of have anything in the area that can ignite fuel The fuel system is pressurized. Before loosening hose connections or opening the test connection), place a cloth around the connection.


16 - Loosen fuel return line from fuel rail (catch escaping fuel with clean rag).
17 - Loosen fuel supply line from fuel rail.
18 - Loosen indicated hose at EVAP valve.
- Unbolt intake manifold from cylinder heads and carefully lift intake manifold from cylinder heads.

Install intake manifold in reverse order. (Tightening torque of bolts: 10 Nm)