Intake Manifold: Service and Repair
Intake manifold/gasket, replacing
Special tools:
951 2957 Coolant Reservoir 951 2957 Coolant Reservoir
951 2953 Cover 951 2953 Cover
Note! 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.
Note! This work requires that the vehicle be raised. See Jacking points, body Service and Repair.
Removal
Removing the upper cross stay
Remove:
- the 4 screws at the suspension turrets
- the screws of the upper engine mount on the engine
- the upper cross stay.
Removing the air cleaner cover
Remove the air cleaner cover by pulling it straight up.
Removing connectors
Remove:
- the 2 connectors from the engine control module (ECM); clip the band clamp to the cable harness
- the connector from the mass air flow sensor
Removing the air cleaner (ACL)
Remove:
- the brake vacuum hose from the vacuum pump
- the 2 screws of the fresh air hose in the front plate
- the fresh air hose
- the air cleaner by pulling it straight up.
Removing the upper engine covers
Remove the upper engine covers by pulling them straight up.
Removing the cover over the servo pump
Remove:
- the 2 screws on the cover over the servo pump
- the cover.
Removing components
Detach the connector of the pressure and temperature sensor (1).
Remove the 2 vacuum hoses of the check valve of the distribution damper (2).
Removing protective plate
Note! There is a guide sleeve on the upper mounting for the plate. This must be lifted slightly so that the panel can be slid forward.
Remove the 6 screws.
Lift and slide the protective plate forward.
Remove the protective plate.
Draining coolant
Open the cock on the lower left edge of the radiator.
Drain the coolant into a clean receptacle.
Close the cock.
Installing the protective plate
Install:
- the protective plate
- the 6 screws; tighten.
Lower the vehicle.
Removing the upper engine mount
Remove:
- the 4 screws
- the upper engine mount.
Removing the intake manifold
Remove:
- the brake vacuum hose (1) from the intake manifold by releasing the clamp
- the intake hose between the air cleaner and throttle body by releasing the 2 clamps
- the 2 nuts on the throttle body
- the 2 screws on the throttle body.
Bend aside the throttle body.
Detach the 2 coolant hoses - one from the throttle body and one from the coolant distribution pipe.
Removing the intake manifold, continued
Remove:
- the hose clip on the vacuum hose (1)
- the vacuum hose (1)
- the 2 M6 screws on the non-return valve (2) for crankcase ventilation
- the non-return valve for crankcase ventilation (2).
Removing the upper intake manifold
Remove:
- the 21 screws of the upper intake manifold
- the upper intake manifold. Scrap the gaskets.
Draining the fuel system
Drain the fuel system. See: Fuel system, draining, B8444S, B6324S5 Draining The Fuel System.
Removing the fuel rail
Remove:
- the crankcase ventilation hose between the cylinder heads by releasing the 2 clamps
- the 3 screws from the fuel rail
- the 2 screws on the fuel pressure sensor.
Lift the fuel rail assembly with injector straight up and bend it aside.
Removing the lower intake manifold
Remove:
- the 12 screws
- the lower intake manifold. Scrap the gaskets.
Installation
Note! For tightening torques, see: Tightening torque, B8444S [1][2]Specifications.
Cleaning
Clean the gasket surfaces.
Installing the lower intake manifold
Install:
- new gaskets
- the lower intake manifold. Tighten the 12 screws. See Tightening torque, B8444S [1][2]Specifications.
Installing the fuel rail
Hint: Lubricate the O-rings on the injectors with Vaseline or the like.
Install:
- the fuel rail assembly with injector
- the 3 screws of the fuel rail; tighten
- the 2 screws on the fuel pressure sensor
- the crankcase ventilation hose and 2 clamps
Connect the fuel supply line and secure the line in the clamp.
Caution! Make sure there is an audible click during connection.
Installing the upper intake manifold
Install:
- new gaskets
- the upper intake manifold; tighten the 21 screws. See Tightening torque, B8444S [1][2]Specifications.
Installing hoses to the intake manifold
Install:
- the vacuum hose (1)
- the hose clip on the vacuum hose
- the non-return valve for crankcase ventilation (2)
- the 2 screws of the non-return valve. Tighten.
Installing components
Install:
- the connector to the pressure and temperature sensor (1)
- the 2 vacuum hoses of the check valve of the distribution damper (2)
Installing the upper engine mount
Install the upper engine mount. Tighten the 4 M10 screws.
Installing the cover over the servo pump
Install:
- the cover over the servo pump
- the 2 screws; tighten.
Installing the upper engine covers
Position the engine covers and press them into the retainers.
Installing the upper cross stay
Install:
- the upper cross stay between the suspension turrets
- the 4 screws in the suspension turrets; tighten
- the screw of the cross stay mount on the engine; tighten.
Installing the air cleaner (ACL)
Install:
- the air cleaner; tighten the hose clip on the mass air flow sensor
- the brake vacuum hose on the brake pump
- the fresh air hose
- the 2 screws of the fresh air hose in the front plate
- the 2 connectors to the engine control module (ECM)
- the connector to the mass air flow sensor
- the band clamp on the cable harness in the air cleaner housing
- the cover over the air cleaner.
Check
Caution! Make sure the outlet hose of filling equipment is not blocked as this could damage the cooling system.
Fill with coolant using filling equipment 951 2957 Coolant Reservoir 951 2957 Coolant Reservoir and cover 951 2953 Cover 951 2953 Cover.
Start the engine and allow it to warm to normal operating temperature. Check for leaks and proper function. Fill up fluids as necessary.