Intake Manifold Gasket: Service and Repair
Intake manifold gasket, replacement
Warning! Disconnect battery ground strap before beginning to work on fuel or electrical system. Do not smoke or have anything in the area which can ignite or cause sparks.
The new routing of the charge air pipe affects intake manifold gasket replacement on turbocharged engines.
The new routing has been implemented into production from:
Preparations:
Remove:
- Battery negative lead.
- Throttle pulley cover.
- Throttle control cable.
Remove:
- Ignition lead cover.
- Upper hose ( A ) from cylinder head crankcase ventilation oil trap.
Removing fuel rail and injectors
Remove:
- Fuel rail cover.
- Connectors and mountings from injectors.
- Clamps (2) holding fuel lines.
Install:
Early fuel rail:
- 5 clamps 999 5533 Holder 999 5533 Holder on the injectors.
Later fuel rail (with bayonet coupling):
- 4 clamps 999 5533 Holder 999 5533 Holder and 1 clamp 999 5620 Clamp injector valve 800 95- 1PC 999 5620 Clamp Injector Valve 800 95- 1PC on the injectors. Position clamp 999 5620 Clamp injector valve 800 95- 1PC 999 5620 Clamp Injector Valve 800 95- 1PC closest to the fuel pressure line as illustrated below.
Press in the clamps so that they are in good contact with injectors.
- Screw down adjustment screw so that the contact plate is in contact with the fuel rail, turn the screw another half turn.
The Figure shows clamp 999 5620 Clamp injector valve 800 95- 1PC 999 5620 Clamp Injector Valve 800 95- 1PC positioned closest to the fuel pressure line (late fuel rail).
Remove:
- Vacuum hose from pressure regulator.
- Screws holding fuel rail.
- Lift the fuel rail twisting it carefully. Hook the middle injector behind the sealing moulding, mounted on the draining channel.
Note! Handle injectors carefully so as not to damage fuel jets and fuel needles. Keep any rubber insulators in the intake manifold.
Removing engine coolant fan (FC)
Remove:
- Front air intake and inlet hose to the air cleaner (ACL).
- Air duct to the control modules box.
- Engine coolant fan (FC) screws (4).
Lift the upper air guide with the relay out of position.
Remove the two spacer washers located above.
Remove:
- Charge air pipe between the intercooler (CAC) and hose on the throttle body (TB).
- Two screws retaining the EVAP valve.
- EVAP hose from the clips on the FC shroud.
Engines with EGR systems:
Pull the EGR converter out of the track from upper air guide.
All:
Disconnect the two connectors to the FC.
Remove the cable from the tie strap and the clip on the FC shroud.
Place the air guide with the relay on the engine
Remove the FC. Pull FC and shroud upward.
Cover the radiator with protective panel P/N 999 5474 RADIATOR PROTECTION 999 5474 Radiator Protection.
Removing hoses and connectors
Remove:
- Idle air control (IAC) valve and throttle position (TP) sensor connectors.
- Hose to brake servo cylinder.
- Hoses from multi-nipple and intake manifold.
- Disconnect EGR temperature sensor.
- Injector cable harness tie strap.
Removing intake manifold
Remove:
- Intake manifold three upper bolts.
- Dipstick and mounting from intake manifold.
- Remove the lower intake manifold bolts.
- EGR valve pipe coupling.
- Intake manifold support bracket screw.
- Intake manifold, by lifting it approx. 20 mm (0.787 in) to free it from the engine.
- Crankcase ventilation hose from intake manifold at servo pump (only 1995 year model).
- Intake manifold gasket.
Clean gasket faces on cylinder head and intake manifold.
Reinstalling intake manifold
Install:
- New gasket and the four lower intake manifold bolts.
- 1995 year model: Crankcase ventilation hose to intake manifold at servo pump.
- All: Intake manifold.
Note! Do not pinch the crankcase ventilation hose between the cylinder head and intake manifold.
- Reinstall the EGR valve on the pipe. Tighten the EGR valve coupling to 50 Nm (37 ft lbs) .
- Upper intake manifold screws and tighten all bolts to 20 Nm (14.8 ft lbs) .
- Intake manifold support bracket screw.
- Dipstick.
Reinstalling hoses and connectors
Reinstall:
- Injector cable harness tie strap.
- Connect EGR temperature sensor.
- Intake manifold hoses
- Multi-nipple hoses
- Hose to brake servo cylinder.
- Idle air control (IAC) valve and throttle position (TP) sensor connectors
Reinstalling engine coolant fan (FC)
Reinstall:
- FC with shroud on the radiator. Locate the air guide with the relay on the radiator.
- Fasten the cable in the tie strap and the clip on the FC shroud.
Reinstall:
- EVAP valve on the FC shroud.
- Two clips on EVAP hose on FC shroud.
- Charge air pipe between the intercooler (CAC) and hose on the throttle body (TB).
- Slide the EGR converter into the track in the upper air guide and check that it is securely in place.
Connect FC connectors.
Reinstall:
- Two spacer washers in the tracks
- Engine coolant fan (FC) shroud and upper air guide with four screws.
- Throttle control cable.
- Throttle pulley cover.
- Air duct to the control modules box.
- Air intake and intake hose for air cleaner (ACL).
Reinstalling fuel rail
Reinstall:
- All rubber insulators in the intake manifold.
- Fuel rail and two fuel line clamps.
- New screws and tighten to 10 Nm (7.4 ft.lbs) .
- Remove tools holding injectors.
- Remove tie strap.
- Pressure regulator vacuum hose.
- Connectors on injectors. Check that there is a rubber seal in each connector.
- Fuel rail cover.
Reinstall:
- Battery negative lead.
Verify operation.
Reprogram radio.