Engine - Intake Manifold

Engine - Intake Manifold

Published: 11-May-2011

Engine - Intake Manifold

In-vehicle Repair

Special Tool(s)

/ Quick Fit Connector Release Tool
310-044
/ Quick Fit Connector Release Tool
310-054

Removal

WARNINGS:

Place the vehicle in a quarantined area and arrange "No Smoking/Petrol Fumes" signs about the vehicle.

Before any work is carried out on the fuel system, ground the vehicle to earth and maintain the ground connection until the work is complete.

Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.

The fuel system remains pressurized for a long time after the ignition is switched off. The fuel pressure must be relieved before attempting any repairs. Failure to follow these instructions may result in personal injury.

After carrying out repairs, the fuel system must be checked visually for leaks. Failure to follow these instructions may result in personal injury.

This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury.

If taken internally do not induce vomiting, seek immediate medical attention. Failure to follow these instructions may result in personal injury.

If fuel contacts the eyes, flush the eyes with cold water or eyewash solution and seek medical attention.

Wash hands thoroughly after handling, as prolonged contact may cause irritation. Should irritation develop, seek medical attention.

Do not carry or operate cellular phones when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.

E33291 /
  1. Disconnect the battery ground cable.
  2. Remove the battery cover.

  1. Release the fuel system pressure. For additional information refer to section 310-00

  1. WARNINGS:
Never remove the coolant expansion tank pressure cap under any circumstances while the engine is operating. Failure to follow this instruction may result in personal injury.
To avoid hot coolant or steam blowing out of the cooling system, use extreme care when removing the coolant expansion tank pressure cap. Wait until the engine has cooled down, then insulate the coolant pressure cap with a suitable cloth and slowly loosen the coolant expansion tank pressure cap until the cooling system pressure is released. Do not remove the coolant expansion tank pressure cap. Step back while the pressure is released from the system. When all of the pressure has been released slowly remove the coolant expansion tank pressure cap (still with the suitable cloth in position) from the coolant expansion tank. Failure to follow this instruction may result in personal injury.
Release the cooling system pressure.
  • Remove the coolant expansion tank pressure cap.

E34122 /
  1. Disconnect the intake tube from the throttle body.
  2. Remove the two bolts which secure the intake tube to the throttle body.
  3. Disconnect the intake tube from the throttle body.

E32805 /
  1. Disconnect the air cleaner cover.
  2. Release the five clips which secure the air cleaner cover.

E34147 /
  1. Disconnect the mass air flow meter electrical connector.
  2. Disconnect the breather pipe from the camshaft cover.
  3. Disconnect the mass air flow meter electrical connector.

E34124 /
  1. Remove the intake tube / air flow meter / air cleaner cover assembly.
  2. Remove the intake tube / air flow meter / air cleaner cover assembly.
  3. Remove and discard the rubber seal; air intake tube to throttle body.

E37492 /
  1. Detach the coolant pipe.

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  1. Remove the engine left-hand cover.

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  1. Disconnect the throttle body electrical connectors.

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  1. Detach the right-hand camshaft position (CMP) sensor wiring harness.

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  1. Disconnect the brake booster vacuum pipe.

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  1. NOTE: Cap the coolant hoses to minimize coolant loss.
Disconnect the throttle body coolant hose.
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  1. NOTE: Right-hand shown, left-hand similar.
Remove the throttle body elbow lower retaining bolts.
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  1. NOTE: Cap the coolant hoses to minimize coolant loss.
Disconnect the throttle body coolant hose.
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  1. Disconnect the accelerator inner cable.
  2. Reposition the accelerator pulley to the full throttle position.
  3. Disconnect the accelerator inner cable.

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  1. Disconnect the accelerator outer cable.
  2. Remove and discard the retaining strap.
  3. Disconnect the accelerator outer cable.

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  1. Disconnect the throttle body electrical connectors.

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  1. Detach the left-hand CMP sensor wiring harness from the throttle body elbow.

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  1. Disconnect the knock sensor (KS) electrical connectors.

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  1. NOTE: Left-hand shown, right-hand similar.
Disconnect the fuel injectors electrical connectors.
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  1. NOTES:
Place an absorbent cloth underneath fuel connection to absorb any spillages.
Cap the fuel line and fuel injection supply manifold to prevent contamination.
Disconnect the fuel feed hose.
  1. Disconnect the fuel feed hose at the Quick Fit connector, using special tool 310 - 044.

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  1. NOTES:
Place an absorbent cloth underneath fuel connection to absorb any spillages.
Cap the fuel line and fuel injection supply manifold to prevent contamination.
Disconnect the fuel return hose.
  1. Disconnect the fuel return hose at the Quick Fit connector, using special tool 310 - 054.

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  1. Disconnect the engine breather hose from the throttle body elbow.
  2. Disconnect the vacuum hose from the throttle body elbow.
  3. Disconnect the engine breather hose from the throttle body elbow.

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  1. Remove the intake manifold.

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  1. Remove and discard the eight seals from the intake manifold ports.

Installation

  1. Clean all parts and relevant mating faces.

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  1. Install eight new seals to the intake manifold ports.

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  1. Install the intake manifold.
  2. Tighten to 21 Nm.

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  1. Connect the engine breather hose to the throttle body elbow.
  2. Connect the vacuum hose to the throttle body elbow.
  3. Connect the engine breather hose from the throttle body elbow.

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  1. NOTES:
Uncap the fuel line and fuel injection supply manifold.
Remove and dispose of absorbent cloth whilst complying to local health and safety standards.
Connect the fuel feed hose.
  1. Connect the fuel feed hose at the Quick Fit connector. Ensure that the hose is fully seated to the feed pipe.

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  1. NOTES:
Uncap the fuel line and fuel injection supply manifold.
Remove and dispose of absorbent cloth whilst complying to local health and safety standards.
Connect the fuel return hose.
  1. Connect the fuel return hose at the Quick Fit connector. Ensure that the hose is fully seated to the feed pipe.

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  1. NOTE: Left-hand shown, right-hand similar.
Connect the fuel injectors electrical connectors.
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  1. Connect the KS electrical connectors.

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  1. Attach the right-hand camshaft sensor wiring harness to the throttle body elbow.

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  1. Connect the throttle body electrical connectors.

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  1. Connect the accelerator inner cable.
  2. Reposition the accelerator pulley to the full throttle position.
  3. Connect the accelerator inner cable.

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  1. NOTE: Uncap the coolant hose.
Connect the coolant hose to the throttle body.
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  1. NOTE: Right-hand shown, left-hand similar.
Install the intake elbow lower retaining bolts.
  • Tighten to 18 Nm.

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  1. NOTE: Uncap the coolant hose.
Connect the coolant hose to the throttle body
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  1. Attach the brake servo vacuum pipe to the throttle body elbow.

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  1. Attach the left-hand CMP sensor wiring harness to the throttle body elbow.

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  1. Connect the throttle body electrical connectors.

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  1. Install the engine right-hand cover.

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  1. Install the engine left-hand cover.

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  1. Attach the coolant pipe.

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  1. Install the intake tube / air flow meter / air cleaner cover assembly.
  2. Install a new rubber seal; air intake tube to throttle body.
  3. Install the intake tube / air flow meter / air cleaner cover assembly.

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  1. Connect the mass air flow meter electrical connector.
  2. Connect the breather pipe from the camshaft cover.
  3. Connect the mass air flow meter electrical connector.

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  1. Reconnect the air cleaner cover.
  2. Install the five clips which secure the air cleaner cover.

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  1. Connect the intake tube to the throttle body.
  2. Install the two bolts which secure the intake tube to the throttle body.
  3. Connect the intake tube from the throttle body.

  1. Fill the cooling system to the correct level.

  1. Install the coolant expansion tank pressure cap.

  1. Carry out the battery reconnection procedure. For additional information refer to Section 414-01.

  1. Adjust the accelerator cable.
    For additional information, refer to Section 310-02 Acceleration Control.

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