Intake Manifold: Service and Repair

1. Remove air mass meter and intake hose
- Disconnect battery ground lead.
- Undo connector at air mass meter.
- Disconnect idling valve lead and air hose.
- Remove flame trap holder (bayonet fitting) Remove intake hose.





2. Remove throttle pulley cover





3. Disconnect/remove:
- throttle switch lead
- throttle cable
- cruise control vacuum servo
- cable bracket at throttle pulley
- vacuum hoses (two) at throttle housing





4. Remove fuel distribution manifold and injectors
- Remove injector cover plate.
- Undo distribution manifold retaining bolts (three).
- Undo injector connectors.
- Disconnect pressure regulator vacuum hose and fuel line bracket.
- Carefully lift out injector/ distribution manifold assembly.





5. Remove:
- air preheater inlet hose
- left and right-hand power stage connectors on bottom of manifold

Undo manifold bottom mounting.





6. Disconnect:
- vacuum hoses (two) under manifold
- brake servo vacuum hose





7. Separate intake manifold
- Cut away clamps securing rubber sleeves between manifold sections (clamps are not reusable).
- Withdraw and lift out manifold (outer section).





8. Remove inner section of manifold
- Remove upper bolts and slacken lower bolts.





9. Transfer to new manifold:
- connection nipples
- throttle housing
- throttle pulley
- throttle bracket
- connector





10. Reinstall inner section of manifold
- Install rubber sleeves on inner section and lubricate free ends with Vaseline.
- Use new gasket.
- Tighten bolts from center outwards.
Tighten to: 20 Nm (15 ft. lbs.)





11. Reinstall outer section of manifold
- Pass wiring between second and third branches.
- Place manifold in position against lower mounting.
Place crankcase ventilation hoses (two) in position.
- Insert manifold branches in rubber sleeves.
Fit and secure with new Oetiker clamps.
- Reconnect vacuum hoses and brake servo hose.
Tighten manifold lower mounting.
- Reconnect power stage connectors and air preheater hose.






12. Install fuel distribution manifold and injectors
- Inspect injector O-rings. Lubricate with water-free Vaseline.
- Reconnect fuel pressure regulator vacuum hose.
- Press fuel distribution manifold into position.
- Tighten manifold.
- Reconnect injector connectors.
- Reconnect ECC vacuum hoses (two).
- Reinstall injector cover.





13. Install/reconnect:
- throttle cable
- cruise control vacuum unit
- vacuum hoses (two) to throttle housing,
- throttle pulley cover





14. Install air mass meter and intake hose
- Reconnect crankcase ventilation hoses (two).
- Reconnect idling valve teed and air hose.
- Reconnect air mass meter and throttle housing connector.
- Install cable bracket a, throttle pulley.





15. Check operation
- Reconnect battery ground lead.
- Test-run engine.