Intake Manifold/Gasket, Replacing

Intake Manifold/Gasket, Replacing

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.

Removal

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 throttle body (TB). Fold to one side
- the protective cover over the nozzle connectors
- the connectors from the nozzles.

- 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.
- Separate the quick-release fuel line connector by pressing the blue clips on both sides.

Remove (only when replacing the intake manifold):







- all 4 vacuum hoses from the intake pipes. (See the above figure)
- disconnect the connector on the Positive temperature coefficient (PTC) nipple for crankcase ventilation (5).

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)
- unscrew the 4 uppermost screws completely. Slacken off the 3 lower screws a few turns
- the intake manifold. Lift the intake manifold approximately 20 mm. Allow the crankcase ventilation hose to run through the intake manifold without disconnecting it from the flame trap
- the hose on the Positive temperature coefficient (PTC) nipple for crankcase ventilation. Lift out the intake manifold.

Transferring components
- Transfer the electronic throttle module.
- Use a new gasket.

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 hose for the Positive temperature coefficient (PTC) nipple
- the lower screws. Tighten all the screws starting from the center
- the screw at the support bracket (under the intake manifold).

Finishing

Install:







- the fuel rail and the injector nozzles. Use new screws. Press the quick-release connector together until a clicking sound is heard.
- the connectors on the injectors and manifold absolute pressure (MAP) sensor in the fuel line and Positive temperature coefficient (PTC) nipple
- the cover plate over the injectors
- the crankcase ventilation hose on top of the cam cover. Use a new clamp
- the vacuum hoses
- the inlet hose between the air cleaner (ACL) and throttle body (TB)
- the cover over the ignition coils
- connect the connector to the throttle body (TB)
- the dip stick in the intake manifold
- clips for the delivery line.

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.