Intake Manifold: Service and Repair

Intake Manifold

Removing

- Remove engine cover.





- Remove air intake hose between air filter and throttle valve control module.





- Open fuel supply and fuel return line - 1 and 2 -.





• Engine code BGK has no fuel return line.

- Remove vacuum hose - - arrow - - from fuel pressure regulator (not on engine code BGK).





- Remove vacuum diaphragm - 1 - and hose - 2 - from throttle valve control module.





- Remove electrical connector from Secondary Air Injection (AIR) Solenoid Valve (N112) and from throttle valve control module.

- Remove bracket from Secondary Air Injection (AIR) Solenoid Valve (N112).





- Remove connecting hose of crankcase ventilation.





- Remove vacuum supply - 1 - for intake manifold change-over on intake manifold.

- Disconnect vacuum supply at T-connector - 2 -.





• The illustration is only an example. It shows the 3.7L BFL engine.

- Remove connector from manifold change-over valve.

- Disconnect connector from Hall sensor (bank 1) and from camshaft adjustment valve (bank 2).

- Disconnect all 8-pin connectors from fuel injectors.

- Set both connector strips to the side.

- Remove all socket head cap screws from intake manifold.

- Carefully pull intake manifold up and out. Water connection on throttle valve control module remains connected.

- Set intake manifold to the side, paying attention to the water connection.

• Plug the intake ports of the cylinder head with clean rags.

Installing

Installation of intake manifold is in reverse order of removal. Note the following.

• Replace all seals.

• Use a lubricant (silicone-free) for installing the intake hose.

• All cable ties which are opened or cut open when removing, must be replaced in the same position when installing.

• Secure all hose connections again using original hose clamps.

- Replace intake manifold gaskets, thereby removing locking bolt - 1 -.

- Note positioning pin when installing intake manifold.





- Bolt on intake manifold in diagonal sequence in stages.

- Check fuel system for leaks => [ Fuel system, checking for proper
seal ] Fuel Pressure Regulator and Residual Pressure, Checking.

Tightening Specifications