Intake Manifold: Service and Repair
Intake manifold/gasket, replacing
Special tools:
951 2666 Replaced by 9997298 951 2666 Wrench (Replaced by 9997298)
Preparation
Remove
- the negative battery cable.
First read Battery, disconnecting Battery Disconnecting.
- the plastic charge air pipe and the hose of the charge air cooler.
- the intake manifold between the air cleaner and turbocharger.
Detach the air cleaner housing intake pipe from the connection above the radiator. Twist the pipe up.
Drain the fuel line. See Fuel system pressure release Fuel System Pressure Release.
Remove
- the cover over the injector connectors.
- the connectors from the injectors.
- the fuel rail mounting screws.
Open the fuel line's quick-release connector using tool 951 2666 Replaced by 9997298 951 2666 Wrench (Replaced by 9997298).
Spray universal oil or the like around the injectors' connection on the intake pipe.
Bend and carefully pull loose the fuel rail and injectors.
Note! Handle the injectors carefully to avoid damaging the injectors' fuel nozzle with needle.
Remove
- The canister purge (CP) valve from mounting on the fan shroud.
- the tie strap holding the wiring to the fan shroud.
Lift the hose for the expansion tank from the holders at the top edge of the fan shroud.
Disconnect both engine cooling fan connectors.
- the two screws holding fan shroud in place. Carefully lift engine cooling fan.
- the plastic charge air pipe between the charge air cooler and throttle body.
Unplug the throttle body connector.
- the dipstick tube's mounting at the intake manifold
Mark up and remove the vacuum hoses from the intake manifold.
Removing the intake manifold/gasket
Remove the upper screws.
Remove the outer screws of the lower row.
Undo the remaining screws.
Lift up and remove the intake manifold.
Remove the remaining screws and the gasket.
Transferring components when replacing the intake manifold
Transfer the throttle body using a new gasket. Tighten to 10 Nm.
Installing the intake manifold/gasket
Make sure that the gasket faces are thoroughly clean.
Install a new gasket with the three center screws in the lower row.
Lower the intake manifold over the three screws.
Install the remaining screws.
Note! Make sure that the holes of the fuel rail are secured with the screws of the lower row and that the hose from the oil trap goes through the intake manifold at cylinders 3 and 4.
Tighten all screws to 20 Nm.
Finishing
Plug in the throttle body connector.
Install
- the vacuum hoses using the previous markings.
- the screw of the dipstick mounting to the intake manifold. Tighten to 25 Nm.
- the plastic charge air pipe between the charge air cooler and throttle body.
Carefully lower the fan shroud. Align it with the holders at the sides of the radiator.
Tighten the two mounting screws.
Connect the engine cooling fan (FC) connectors.
Press the hose from the expansion tank down into the holders on the fan shroud.
Secure the wiring with tie straps as before.
Press the evaporative emission system (EVAP) valve into the holder on the fan shroud.
Apply Vaseline to the injector rings.
Hold the fuel rail in place. Press the fuel line's quick-release connector together until it "clicks".
Press down the fuel rail. Check that all injectors are correctly positioned.
Tighten the fuel rail to 10 Nm using new screws.
Plug in all injector connectors.
Install
- the intake manifold between the air cleaner and turbocharger.
- the plastic charge air pipe and the hose of the charge air cooler.
Turn down the air cleaner (ACL) intake manifold and locate against the sleeve connector above the air conditioning aggregate.
- the negative battery cable.
First read Battery, disconnecting Battery Disconnecting.
Test drive the engine.