Intake Manifold/Gasket, Replacing

Intake manifold/gasket, replacing

Note! Since 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. First read Battery, disconnecting Battery Disconnecting.
Drain the fuel system. See Fuel tank, draining Service and Repair.
Remove the thermostat housing according to Replacing the thermostat and/or engine coolant temperature sensor Replacing the Thermostat and/or Engine Coolant Temperature Sensor





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. See Fuel line, lock Service and Repair.





Remove (only when replacing the intake manifold):
- all 4 vacuum hoses from the intake pipes. (See the illustration)
- 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.

Installation

Note! For tightening torques, see Tightening torque Tightening Torque.

Installing the intake manifold and gasket

Note! Make sure 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. See Fuel line, lock Service and Repair
- 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.
- thermostat housing according to Replacing the thermostat and/or engine coolant temperature sensor Replacing the Thermostat and/or Engine Coolant Temperature Sensor
Install the battery negative lead. First read Battery, disconnecting 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.