Intake Manifold: Service and Repair

Intake manifold/gasket, replacing

Removal

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 in the illustrations is always correct.

Preparation





Remove
- the battery negative lead.
First read: Battery, disconnecting Battery Disconnecting.
- plastic charge air pipe and hose to charge air cooler (CAC)
- the intake pipe between the air cleaner (ACL) and the turbocharger (TC).
Remove the intake pipe for the air cleaner (ACL) housing from the connection above radiator. Twist the pipe up.
Depressurize the fuel system acc. to Fuel system pressure release Fuel System Pressure Release.





Remove
- the protective cover over the injector connectors
- injector connectors
- the fuel rail mounting screws.

Note! Handle the injectors carefully to avoid damaging the fuel nozzles and fuel needles.

Spray universal oil or similar around the injector terminals on the intake manifold.
Gently work the fuel rail and injectors loose.
Detach the fuel line from the nozzle pipe by pressing the quick-release connector.





Remove
- the dip stick pipe mounting at the intake manifold
- the nipple for the crankcase ventilation under the intake
- disconnect the throttle body (TB) connector. Remove the plastic charge air pipe from the throttle body (TB).

Removing the intake manifold and gasket




Remove the upper screws.
Remove the outer screws from the lower row.
Slacken off the remaining screws.
Lift up and remove the intake manifold.
Remove the remaining screws and gasket.

Installation

Note! For tightening torques, see Specifications, B6324S Tightening Torque.

Transferring components when replacing intake manifold
Transfer the throttle body using a new gasket. Tighten to 10 Nm.

Installing intake manifold / gasket




Make sure that the gasket faces are clean.
Install a new gasket with the two centermost screws in the lower row.
Lower the intake over the 2 screws.
Install the remaining screws.
Tighten all the screws with 20 Nm.

Finishing
Connect the throttle body (TB) connector.





Install
- the vacuum hoses according to the earlier markings
- the nipple for the crankcase ventilation under the intake manifold
- the dip stick mounting screw to the intake manifold. Tighten to 25 Nm
- the plastic charge air pipe between the throttle body (TB) and the charge air cooler (CAC).




Lubricate the injector rings with petroleum jelly.
Hold the fuel rail. Press together the fuel line quick-connector until you hear a "click".
Press down the fuel rail. Check that all injectors are correctly positioned.
Tighten the fuel rail to 10 Nm using new screws.
Connect all the connectors to the injectors.
Install the protective cover over the connectors to the nozzles.





Install:
- intake manifold between air cleaner (ACL) and turbocharger (TC)
- plastic charge air pipe and hose to charge air cooler (CAC)
- the air cleaner (ACL) intake pipe
- the negative battery lead. First read Battery, disconnecting Battery Disconnecting.
Test drive the engine.