Removing the intake manifold

Fig 1: Identifying Injector Connectors Protective Cover

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove: 

• the crankcase ventilation hose from the top of the cam cover
• the protective cover over the injector connectors.

Disconnect the connectors from: 

• the injectors
• the manifold absolute pressure (MAP) sensor in the fuel line
• the temperature sensor in the thermostat housing. Place the wiring to one side.

Fig 2: Identifying Fuel Rail, Injector, And Connector

Courtesy of VOLVO CARS OF NORTH AMERICA.

• Remove the mounting screws from the fuel rail
• Spray universal oil or similar around the injector nozzle at the terminal on the intake manifold
• Gently work the fuel rail and injector nozzles loose
• Separate the quick-release fuel line connector by pressing the blue clips on both sides. See Fuel line, lock .

Fig 3: Identifying Intake Manifold And Hoses

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove 

• all 4 vacuum hoses from the intake pipe. (see the illustration). Disconnect the connector on the Positive temperature coefficient (PTC) nipple for crankcase ventilation (5).

Fig 4: Identifying Intake Manifold

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove: 

• the screw holding the dip stick pipe to the intake manifold
• the clip for the servo pressure pipe
• the screw at the support bracket (under the intake manifold). Disconnect the connector for the electronic throttle module (ETM)
• unscrew the four upper screws completely. Slacken off the lower screws a few turns
• the intake manifold. Lift the intake manifold approximately 20 mm  . Allow the crankcase ventilation hose to run through the intake manifold without disconnecting it from the flame trap
• the hose on the Positive temperature coefficient (PTC) nipple for crankcase ventilation. Lift out the intake manifold
• the upper coolant hose.