Intake Manifold/Gasket, Replacing

Intake Manifold/Gasket, Replacing

Special Tools: 951 2666

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 is always correct.

Replacing the intake manifold and gasket

Removing the intake manifold and gasket
- Disconnect the battery negative lead.
- Drain the fuel injection system.

Remove







- the cover over the ignition coils
- the crankcase ventilation hose from the top of the cam cover
- the inlet hose from the air cleaner (ACL) and throttle body (TB)
- the hose for the vacuum controlled crankcase ventilation from the inlet hose
- the protective cover over the nozzle connectors
- the connectors from the nozzles.







- Separate the fuel line quick-release connector. Use tool 951 2666.
- Remove the mounting screws from the fuel rail.
- Spray universal oil or similar around the injector nozzle at the terminal on the intake manifold.
- Gently work the fuel rail and injector nozzles loose.

Remove (only when replacing the intake manifold)







- all 5 vacuum hoses from the intake manifolds. (See the above figure)

NOTE: Ensure that the plastic nipple (5) located in the terminal at the intake does not follow the hose.

- Remove
- the screw holding the dip stick pipe to the intake manifold
- the screw at the support bracket (under the intake manifold).

Disconnect the connector for the throttle body (TB)

- the mounting screws in the upper row and the outer screws in the lower row
- the intake manifold, by lifting it approximately 20 mm.

Allow the crankcase ventilation hose to run through the intake manifold without disconnecting it from the flame trap.

Transferring components when replacing the intake manifold
- Transfer the electronic throttle module.

Use a new gasket.

Tighten to 10 Nm.

Installing the intake manifold and gasket

NOTE: Ensure that the gasket faces are clean.

Install
- a new gasket held in position by the lower screws for the intake manifold
- the intake manifold
- the crankcase ventilation. The crankcase ventilation must be installed through the gap between the second and third channels
- the three upper screws. Tighten all screws (starting from the center) to 20 Nm
- the screw at the support bracket (under the intake manifold).

Finishing

Install







- the fuel rail and the injector nozzles.

Use new screws. Tighten to 10 Nm. Press the quick-release connector together until a clicking sound is heard.

- the connectors for the injectors and the cover plate
- the crankcase ventilation hose on the top of the cam cover. Use a new clamp
- the vacuum hoses.

Ensure that the plastic nipple, located in the terminal at the intake for the crankcase ventilation hose, is in the correct position

- the inlet hose between the air cleaner (ACL) and throttle body (TB)
- the hose for vacuum controlled crankcase ventilation in the inlet hose
- the cover over the ignition coils
- the connectors to the throttle body (TB)
- the dip stick in the intake manifold.

Install the battery negative lead.

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.