Intake Manifold: Service and Repair

Intake Manifold

Service Repair No - 30.15.02

Removal

NOTE: Removal of the intake manifold on early vehicles will involve the partial dismantling of the fuel rail and the removal of the purge valve and mounting bracket. Once removed, it will also be necessary to remove some excess material from the intake manifold, see 'installation' graphics.

1. Secure the hood in the service position.
^ Release the support struts.
2. Disconnect the battery ground cable.
3. Remove the throttle body gasket.





4. Disconnect the 2 coolant hoses.
^ Clamp the relevant hoses, to minimize the coolant loss.
^ Release the 2 clips.

5. CAUTION: Before the disconnection or removal of any components, ensure the area around joint faces and connections are clean. Plug any open connections to prevent contamination.

Disconnect the crankcase vent hose.
6. Disconnect the exhaust gas recirculation (EGR) valve vacuum hose.





7. Disconnect the brake booster vacuum hoses and move aside for access.
^ Remove and discard 2 cable ties.
8. Remove the ignition coil.
9. Remove the 5 remaining ignition coils.





10. Release the coil wiring harness.
^ Release the 4 clips.





11. Release the 6 plug lead clips.
12. Remove the EGR valve.





13. Disconnect the intake manifold vacuum pipe assembly.





14. Disconnect the intake manifold tuning valve electrical connector.





15. Position the engine wiring harness aside for access.





16. Remove the 8 intake manifold bolts.





17. Right hand drive models only: Release the intake manifold wiring harness clip.





18. WARNING: The spilling of fuel is unavoidable during this operation. Ensure that all necessary precautions are taken to prevent fire and explosion.

CAUTION: Always carry out the cleaning process before carrying out any repairs to the fuel injection system components. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.

Release the fuel rail and injectors.
^ Remove the 4 bolts.
^ Remove the bolt and release the valve cover fuel line clip.
^ Disconnect the LH and RH cylinder head, rear fuel injector electrical connectors.





19. /CAUTION: Care must be taken to avoid damaging the purge vale assembly during removal of the intake manifold.

NOTE: Due to the lack of access it may be necessary to break the engine and transmission wiring harness clips, care must be taken not to damage the wiring harnesses.

Release and then remove the intake manifold.
^ Discard the gaskets.
^ Remove the bracket from the purge valve assembly.
^ Remove and discard the bolt.
^ Cable tie the purge valve to the wiring harness.

Installation





1. WARNING: Make sure there are no sharp edges after removing material.

Early models only: Remove the center casting lug.





2. Early models only: Remove excess material from the outside edges of the 6 intake manifold flange faces, file to within 2 mm of the gasket edge.
3. Install the fuel rail and injectors.
^ Clean the component mating faces.
^ Tighten the bolts to 25 Nm (18 ft. lbs.).
^ Secure the fuel line.
^ Tighten the M6 bolt to 10 Nm (7 ft. lbs.).
^ Connect the fuel injector electrical connectors.

4. NOTE: Make sure the bolt retainer is correctly located.

Remove and discard the 2 rear intake manifold retaining bolts.
^ Install the 2 service replacement bolts.
5. Right hand drive models only: Secure the wiring harness to the intake manifold.
^ Secure the wiring harness clip.





6. Install the intake manifold.
^ Clean the component mating faces.
^ Install the gaskets.
^ Evenly and progressively tighten the bolts in the sequence shown to 10 Nm (7 ft. lbs.).
7. Position the engine wiring harness.
^ Secure the electrical harness to the purge valve and the harness intake manifold brackets.
8. Connect the intake manifold tuning valve electrical connector.
9. Connect the vacuum pipe to the inlet manifold.
10. Install the EGR valve.
11. Secure the plug leads to the intake manifold with clips.
12. Secure the coil wiring harness.
13. Install the ignition coil.
14. Install the remaining ignition coils.
15. Connect the brake booster vacuum hoses.
^ Clean the component mating faces.
^ Secure with cable ties.
16. Connect the EGR vacuum hose to the intake manifold.
^ Clean the component mating faces.
17. Connect the crankcase vent hose.
^ Clean the component mating faces.
18. Install the throttle body gasket.
19. Connect the coolant hoses.
^ Secure with the clips.
^ Remove the hose clamps.
20. Check and top-up the coolant.
21. Connect the hood support struts.
22. Connect the battery ground cable.