Intake Manifold

Intake Manifold

Removing

• All cable ties which are opened or cut open when removing, must be replaced in the same position when installing.

Observe safety precautions when disconnecting the battery.

- Clamp off battery Ground (GND) wire with ignition switched off.

- Remove air filter element. Refer to => [ Air Filter ] Air Filter.

- Remove air filter housing. Refer to => [ Air Filter Housing ] Air Filter Housing.

- Disconnect electrical connectors - 1, 2, 3 - and free up electrical wires.





- Disconnect crankcase ventilation hose - 4 -.

- Remove ignition coils. Refer to => [ Ignition Coils ] Service and Repair.

- Remove the Throttle Valve Control Module (J338). Refer to => [ Throttle Valve Control Module ] Throttle Valve Control Module.

- Remove vacuum hoses - 1, 3, 4 - back from intake manifold.





Vehicles with engine code CBRA:

- Remove the vacuum hose - 2 - for the leak detection pump (V144).

All Vehicles

- Remove line union from intake manifold - arrows - and place it in the rear with hoses connected.

- Remove bolts - arrows - for rear intake manifold mount.





- Disengage harness connector - arrow - for Engine Speed (RPM) Sensor (G28) from bracket on oil dipstick guide tube.





- Remove dipstick.

- Remove bolt - 3 -, remove oil dipstick guide tube - 2 - and lay it aside.





- Remove bolt - 4 - and remove vacuum reservoir - 1 - from intake manifold.

- Set aside vacuum reservoir with lines still connected.

- Release relay lever - arrow - and remove it.





- Remove the bolts - 1 - and - 2 -.

- Remove intake manifold change-over actuator from intake manifold and lay it aside with vacuum hose connected - 3 -.

- Remove bolts - arrows - and remove left engine lifting eye.





- Remove bolts - arrows - at front on intake manifold.





- To prevent surface damage to the intake manifold, lay a clean cloth - 1 - over the lock carrier.





- Tip intake manifold forward - arrow A - and remove it to the left - arrow B -.

• Seal intake channels in cylinder head with clean rags or foam pieces so that small pieces cannot fall in.

Installing

• Tightening specifications, refer to => [ Intake Manifold Assembly Overview ] Intake Manifold Assembly Overview.

Installation is in reverse order of removal, note the following:

• Replace seals.

- Install ignition coils. Refer to => [ Ignition Coils ] Service and Repair.

- Install throttle valve control module (J338). Refer to => [ Throttle Valve Control Module ] Throttle Valve Control Module.

- Install air filter housing. Refer to => [ Air Filter Housing ] Air Filter Housing.

- Install air filter insert. Refer to => [ Air Filter ] Air Filter.

- Connect Ground (GND) cable to battery.