Contents: Removal ↳ Installation ↳
Please note: The design of the intake manifold and its fittings varied significantly depending on the year of manufacture, engine output and the equipment installed (eGR system, turbocharging, electronic engine control, etc.). The following procedures cover the removal and reinstallation of the manifold with specific ancillary components. If necessary, other components can be removed later as described in the relevant sections of this guide.
Removal
1. Disconnect the negative battery cable.
2. Separate the air cleaner inlet pipe from the intake manifold, or remove the air cleaner assembly, according to the engine type (see Figure 18.2).
Figure 18.2. Separate the air cleaner inlet pipe from the intake manifold.
3. To remove the fuel filter, unscrew the two bolts securing it to the intake manifold. Place the filter as far from the manifold as the fuel lines will allow.
4. Disconnect the engine breather hose from the manifold.
5. On engines with an Exhaust Gas Recirculation (EGR) system, disconnect the EGR connection tube from the throttle body and remove the metal gasket, if equipped. Disconnect the throttle control lever (see Figure 18.5,a).
Figure 18.5,a. Disconnect the EGR system connection hose from the throttle body and remove the metal gasket.
Figure 18.5, b....or, on later models, remove the clamping ring (indicated by the arrow) and release the hose.
Figure 18.5, d. Disconnect the throttle control lever from the housing.
6. On turbocharged engines, loosen the hose clamps and disconnect the intake manifold where the hose attaches to the intake manifold.
7. Disconnect any remaining hoses and wires as needed.
8. On engines with a two-piece composite intake manifold, remove the bolt securing the manifold to the support bracket. Unscrew the nuts and bolts and separate the upper part of the manifold from the lower part. Remove the gasket between the two halves (see Figure 18.8, a-g).
Figure 18.8a. On engines with a composite intake manifold, unscrew the bolt (indicated by the arrow), attaching the manifold to the support bracket.
Figure 18.8b. Unscrew the nuts and bolts...
Figure 18.8v....separate the upper part of the manifold from the lower section.
Figure 18.8g.... and remove the gasket between the two halves
9. Unscrew the nuts and bolts securing the manifold to the cylinder head, then remove the manifold and its gasket (see Figure 18.9).
Figure 18.9. Separate the manifold from the cylinder head and remove the gasket.
Installation
10. Installation is carried out in the reverse order of removal. Use new gaskets on the manifold and EGR system connections and tighten all nuts and bolts to specification.