Intake Manifold Removal and Installation

Exploded View
Removal
  1. Remove the intercooler outlet hose.
  1. Remove the vacuum hoses.
  1. Remove the dipstick.
  1. Remove the dipstick tube.
  1. Remove the engine wire harness connectors and wire harness clamps from the intake manifold.
    • Intake manifold runner control (IMRC) solenoid valve connector
    • Manifold absolute pressure (MAP)/intake air temperature (IAT) sensor connector
    • IMRC valve position sensor connector
    • Intake shutter valve (ISV) connector (with DPF)
  1. Remove the water bypass line (A) and the fuel return hose holder (B) from the intake manifold.
  1. Remove the intake manifold bracket (A), then remove the intake manifold (B).
Installation
  1. Install the intake manifold (A) with a new gasket (B), and tighten the bolts and nuts in a crisscross pattern in two or three steps, beginning with the inner bolt.
  1. Install the intake manifold bracket (C).
  1. Install the water bypass line (A) and the fuel return hose holder (B) on the intake manifold.
  1. Install the engine wire harness connectors and wire harness clamps to the intake manifold.
    • IMRC solenoid valve connector
    • MAP/IAT sensor connector
    • IMRC valve position sensor connector
    • ISV connector (with DPF)
  1. Install the dipstick tube (A) with new O-ring (B).
  1. Install the dipstick.
  1. Install the vacuum hoses.
  1. Install the intercooler outlet hose.
  1. After installation, check that all tubes, hoses and connectors are installed correctly.