Intake Manifold: Service and Repair

Intake manifold/gasket, replacing

Special tools:
999 5723 Cap 999 5723 Cap
951 2666 Replaced by 9997298 951 2666 Wrench (Replaced by 9997298)

Preparation
Remove the battery's minus cable. First read: Battery, disconnecting Battery Disconnecting.
Drain the fuel line. See Fuel system pressure release Fuel System Pressure Release.





Remove
- the intake manifold between the air filter housing and throttle module (ETM)
- the screw for the dipstick tube's bracket against the intake manifold
- the hose from the EVAP-valve at the inlet pipe
Mark up and remove the vacuum hoses from upper inlet pipe.
Disconnect the connector for the electronic throttle module (ETM).

Removing the upper inlet pipe




Remove the ten screws at the inlet pipe's parting surface.
Lift off the upper part of the inlet pipe. Install guards 999 5723 Cap 999 5723 Cap.
Remove the connectors for the injection valves.
Remove the screws that hold the fuel rail.
Spray with universal oil or similar around the injectors' connection on the inlet pipe.
Wiggle and carefully pull loose the inlet pipe and injectors.
Part the quick-coupling for the fuel line. Use tool 951 2666 Replaced by 9997298 951 2666 Wrench (Replaced by 9997298).

Note! Handle the injectors carefully to avoid damaging the injectors' fuel nozzle with needle.

Removing the lower inlet pipe




Mark up and remove the remaining vacuum hoses.
Remove the upper screws.
Remove the outer screws in the lower row.
Loosen the remaining screws.
Lift up and remove the lower part of the inlet pipe.

Replacing the gasket




Remove the remaining screws and the gasket.
Clean the gasket surface.
Install new gasket with the two center screws in the lower row.

Transferring parts when replacing inlet pipe





Transfer
- throttle module (ETM). Use new gasket. Tighten with 10 Nm

Installing the lower inlet pipe




Install guards 999 5723 Cap 999 5723 Cap.
Lower the inlet over the three screws.
Install the remaining screws.
Tighten all the screws with 20 Nm.
Install both vacuum hoses according to earlier marking.





Install
- the fuel rail with new screws. Tighten with 10 Nm
- the fuel line's quick-coupling

Note! Check that the coupling is installed correctly.

- The connectors for the injectors.

Installing the upper inlet pipe
Remove guards 999 5723 Cap 999 5723 Cap.
Make sure that the gasket surfaces are clean.
Lay on new gasket.
Hold the inlet pipe and install all screws.
Tighten the screws with 17 Nm.

Finishing




Plug in the connector for the electronic throttle module (ETM).

Install
- the hoses for crankcase ventilation, EVAP-valve and brake booster
- the screw for the dipstick tube's bracket against the intake manifold
- the intake manifold between the air filter housing and throttle module
- the battery's minus cable.
First read: Battery, disconnecting Battery Disconnecting.
Test drive the engine.