Intake Manifold: Service and Repair
Replacing the intake manifold and gasket
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
Remove the front engine cover if applicable.
Disconnect the battery negative lead. First read Note when disconnecting and connecting the battery lead Battery Disconnecting.
Drain the fuel injection system. See Draining the fuel injection system Draining The Fuel Injection System.
Removing the fuel rail
Remove:
- the cover over the ignition coils
- the crankcase ventilation hose from the top of the cam cover
- the cover over the throttle body (TB)
- the protective cover over the nozzle connectors
- the connectors from the nozzles
- the vacuum hose for the fuel pressure regulator from the throttle body (TB).
Removing fuel line
Disconnect the quick-release connector between the fuel line and the fuel rail. Use tool 951 2666 Replaced by 9997298 951 2666 Wrench (Replaced by 9997298).
Remove the mounting screws from the fuel rail.
Gently work the fuel rail and injector nozzles loose as a single unit.
Removing components
Remove:
- the hose from the assisted air control valve in the inlet hose
- the intake hose between the mass air flow (MAF) sensor and throttle body (TB)
- the vacuum hoses from the intake manifold
- the throttle cable
- the connectors from the assisted air control valve and throttle position (TP) switch
- the screw from the cable duct mounting in the throttle body (TB)
- the knock sensor (KS) cable from the clip
- the brake servo hose
- the bracket between the intake manifold and the pump
- the screw holding the dip stick pipe to the intake manifold
- the upper screw for the intake manifold support bracket, slacken the lower a few turns.
Removing the intake manifold
Remove:
- the mounting screws for the intake manifold
- the intake manifold. Allow the crankcase ventilation hose to run through the intake manifold without disconnecting it from the flame trap
- the two water hoses for the coolant and seal so that coolant vapor cannot seep out
- the vacuum hose.
Transferring components when replacing the intake manifold
Transfer the throttle body (TB) and the assisted air control valve. Use new gaskets. Tighten to 10 Nm.
Installing the intake manifold and gasket
Note! Ensure that the gasket faces are clean.
Install:
- a new gasket
- the vacuum hose
- the two heater hoses using a new G-clamp
- the intake manifold. Do not forget the crankcase ventilation hose. The hose must be inserted up through the gap between the second and third ducts
- the screws.
Tighten all the screws starting from the center. Tighten to 20 Nm.
Install and tighten the screws for the support bracket (under the intake manifold).
Installing components
Install:
- the screw holding the dip stick pipe to the intake manifold
- the bracket between the intake manifold and the pump
- the brake servo hose
- the cable for the knock sensor (KS)
- the mounting screw for the cable duct in the throttle body (TB)
- the connectors on the assisted air control valve and throttle position (TP) switch
- the throttle cable
- the vacuum hoses on the intake manifold
- the intake hose between the mass air flow (MAF) sensor and throttle body (TB)
- the hose from the assisted air control valve in the inlet hose.
Installing the fuel rail
Install:
- the fuel rail and the injector nozzles. Press the quick-release connector together until it clicks. Use new screws. Tighten to 10 Nm
- the vacuum hose for the fuel pressure regulator
- the crankcase ventilation hose on the top of the cam cover. Use a new clamp
- the connectors and protective cover for the injectors
- the covers over the ignition coils and throttle body (TB).
Install the battery negative lead. First read Note when disconnecting and connecting the battery lead Battery Disconnecting.
Final check
Test drive the car. Check the following:
- that there is no fuel leakage
- that the engine operates normally.
Clean the engine compartment. Check that everything is in position.
Install the front engine cover if applicable.