Intake Manifold: Service and Repair

INTAKE MANIFOLD

Remove
1. Depressurize fuel system.
2. Disconnect the battery negative lead.
3. Drain cooling system.
4. Remove plenum chamber. Intake Air Plenum
5. Remove intake air resonator housing.

CAUTION: Place a protective cover over intake manifold openings to prevent the ingress of dirt.

6. Disconnect the fuel temperature sensor and injector multiplugs.
7. Remove fuel pressure regulator.




8. Disconnect coolant sensor multiplug.




9. Disconnect instrument pack temperature thermistor.
10. Disconnect coolant sensor multiplug.
11. Loosen clip and disconnect top hose from thermostat housing.
12. Disconnect multiplug from distributor amplifier module.
13. Loosen clip and disconnect hose from heater valve.
14. Remove injector harnesses from behind fuel rail and lay to one side.
15. Loosen union and disconnect fuel return hose from fuel rail.

NOTE: The intake manifold can be removed from the cylinder block without removing the fuel rail and injectors.

Loosening Sequence:

16. Using the sequence shown, remove 12 bolts securing the intake manifold to cylinder block.
17. Remove the Intake manifold.
18. Noting their fitted position, remove bolts and clamps securing intake manifold gasket to cylinder block.
19. Remove and discard gasket.
20. Remove and discard gasket seals.

Do not carry out further dismantling if component is removed for access only.

21. Remove 5 nuts securing fuel rail support brackets to intake manifold.
22. Remove fuel rail and injectors.
23. Remove 2 bolts securing thermostat housing to intake manifold.
24. Remove thermostat housing.
25. Remove bolt securing coolant pipe to intake manifold. Loosen union and remove coolant pipe. Remove and discard O-ring.
26. Fit new O-ring to coolant pipe. Position coolant pipe to intake manifold. Fit bolt securing coolant pipe support bracket to intake manifold and tighten pipe union.
27. Clean mating faces of thermostat housing and intake manifold.
28. Fit thermostat housing to intake manifold using a new gasket, fit and tighten bolts.
29. Position fuel rail to intake manifold, fit and tighten retaining bolts.


Refit
1. Clean mating faces of cylinder heads, cylinder block and intake manifold.




2. Locate NEW seals in position with ends engaged in notches formed between the cylinder heads and block.
3. Apply RTV sealant between ends of seals, cylinder heads and block.
4. Fit intake manifold gasket with the word FRONT to the front and open bolts hole to the front RH side.
5. Fit gasket clamps and tighten bolts finger tight.
6. Locate intake manifold onto cylinder heads, clean threads of manifold securing bolts.
7. Allow 10 minutes for RTV sealant to cure.

Tightening Sequence:

8. Fit manifold bolts finger tight. Working in the sequence shown tighten the bolts to 38 Nm (28 ft lb).
9. Tighten the gasket clamp bolts to 18 Nm (14 ft lb).
10. Reverse removal procedure.
11. Fill cooling system.
12. Start engine check for water and fuel leaks.