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Intake Manifold Replacement

Intake Manifold Replacement

Removal Procedure


1. Remove the fuel pump. Refer to Fuel Injection Pump Replacement .

2. Remove the EGR pipe. Refer to Exhaust Gas Recirculation Valve Cooler Replacement .

3. Unplug the intake air sensor connector (1) and the glow plug connector (2).


4. Remove the coolant connection (1).


5. Detach the cable bracket 1 screw (1).

6. Detach the exhaust pressure pipe, 1 electrical connector (2), 1 clamp (3) and remove the hose , 2 screw (4).

7. Remove coolant quick connection (5).

8. Remove the oil trap from the engine block, remove the upper hose connection (6), remove the clips (7). Remove the 2 bolts (8) and move the oil trap aside.

9. Unplug the connector (1) of the combustion circulation actuator.


10. Remove the stud (1) holding the high-pressure pump in place. Lock two M8 nuts with each other and remove the bolt.


11. Remove the bolt towards the lifting eye (1).


12. Remove the intake manifold (2).


Installation Procedure


1. Refer to Fastener Caution .

Fit the intake manifold (2) with new seals. Tighten fasteners to 25 Nm (18 lb ft) .


2. Fit the bolt towards the lifting eye (1).

3. Fit the stud (1).


4. Plug in the connector (1) of the combustion circulation actuator.


5. Mount the exhaust pressure pipe, 2 screws (4).1 electrical connector (2), 1 clamp (3) and attach the hose.


6. Fit the oil trap to the engine block, attach the upper hose connection (6), mount the clips (7), mount the 2 bolts (8).

7. Fit the coolant quick connection (5).

8. Attach the cable bracket 1 screw (1).

9. Plug in the intake air sensor connector (1) and the glow plug connectors (2).


10. Fit the EGR pipe. Refer to Exhaust Gas Recirculation Valve Cooler Replacement .

11. Fit the fuel pump. Refer to Fuel Injection Pump Replacement .

12. Connect an exhaust hose and start the engine. Check there are no leaks. Connect the diagnostic tool and erase any diagnostic trouble codes.