Installing Intake Manifold
WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2006 Volvo S80, 2005 Volvo S80, 2004 Volvo S80, 2003 Volvo S80, and 2002 Volvo S80. However, it is still accessible from the selected car via links, so may be relevant.
Clean the intake manifold gasket face to the cylinder head.
Install a new gasket on the cylinder head. Secure with the two screws in the lower row.
Lower and twist the intake manifold so that the fuel pressure line goes through the cavity in the intake manifold.
NOTE:
Work carefully to avoid damaging the fuel pressure pipe.
Route the crankcase ventilation hose through the cavity in the intake manifold.
Install:
- the pipe screw for the crankcase ventilation on the underside of the intake manifold. Use new seal washers. Tighten to 26 Nm
- the rest of the screws holding the intake manifold to the cylinder head. Tighten to 19 Nm
- the hose to the canister purge (CP) valve
- the control hose for the turbocharger (TC) by-pass valve
- the brake vacuum hose
- the crankcase ventilation hose to the top of the camshaft cover. Use a new clamp
- the cover over the ignition coils
- the upper timing cover
- the upper engine coolant hose for the engine and radiator. Tighten the clamp
- the screw holding the dip stick pipe to the intake manifold. Connect the connector to the electronic throttle module (ETM)
- the charge air pipe between the throttle body (TB) and the charge air cooler (CAC). Remove the seal. Tighten the clamp.