Intake Manifold: Service and Repair

Special Tools:
- Holder tool No. 999 5533, or equivalent


NOTE:
- For additional information on special tools and equipment used in this procedure, refer to Service and Repair. Tools For Engine Service and Repair
- The intake manifold is stocked complete with throttle housing and damper spindles for engines with damper spindles.

Procedure





1. Undo fuel distribution manifold with injectors:
- Remove throttle cable and injector cover. Remove throttle cable.
- Disconnect connectors and clips from injectors.
- Remove two clips holding the fuel pipes and remove distribution manifold mounting screws.
- Install five holders 999 5533, or equivalent, carefully pull up injectors together with distribution manifold.
- Disconnect hose from purge valve.
- Carefully place distribution manifold with injectors on engine.

NOTE: Ensure that injectors and needles are not damaged.





2. Disconnect:
- throttle linkage from pulley
- intake air hose to throttle body (TB)
- multi-nipple
- throttle pulley with bracket and idle speed control valve
- EGR-hose clamp (turbo)
- pressure hose to turbo-instrumentation/EGR valve control vacuum hose
- brake servo hose





3. Undo:
- dipstick bracket
- intake manifold screw in lower bracket
- lower intake manifold screws a few turns.
4. Remove:
- remove upper intake manifold screws.
- intake manifold by lifting it approx. 20 mm. (Allow the crankcase ventilation hose run through the intake manifold without disconnecting it from the flame trap, does not apply to turbocharger (TC) models).

NOTE: Check that there are no foreign bodies in the intake manifold before installing it.





5. Install:
- new gasket which is held in place by the lower intake manifold screws. (Do not forget the clamp on the fourth screw on turbo models.)
- intake manifold. (Do not forget the crankcase ventilation hose which comes up through the gap between the second and third ducts on S-engines.)
- three upper screws and tighten all screws from center outwards to 20 Nm (14.8 ft lb).

Part 1 Of 2:

Part 2 Of 2:

6. Install:
- EGR-valve (if fitted) with new gasket
- TB and new gasket
- throttle pulley
- with bracket
- multi-nipple and connect hoses
- fuel distribution manifold and two clips
- wiring and injector cover
- screw for bracket under intake manifold
- dipstick bracket screw
- brake servo hose
- air inlet hose
- idle air control valve
- throttle linkage and throttle cable
- throttle linkage cover