Replacement of intake manifold/gasket: Preparation

Fig 1: Identifying Adapter Connected To Fuel Draining Unit

Courtesy of VOLVO CARS OF NORTH AMERICA.

Drain the fuel system. See Fuel system pressure release .

Fig 2: Identifying Camshaft Components

Courtesy of VOLVO CARS OF NORTH AMERICA.

Method is the same for both aspiration and turbo engines.

The engine compartment figures (above) show a turbo engine.

These figures (above) are not exactly correct since the air pump has been discontinued.

Remove 

• the control module box air baffle.
• cover plate over the injectors.
• the connectors from the injectors.
• connectors for the sensors in plastic charge-air pipe between charge-air cooler and throttle module.
• the cover over the ignition coils

Part the connector for the electronic throttle body.

Part the charge-air pipe at hose/plastic pipe.

Remove the plastic charge-air pipe.

Seal the opening.

Mark up and remove the vacuum hoses from the intake pipe.

• the cover over the ignition coils

Remove the hose from the oil trap for the cam cover at the connection in the cam cover.

Fig 3: Identifying Intake Manifold

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove the mounting screws from the fuel rail.

Part the fuel line's quick-coupling.

Use tool 9512666 .

Spray universal oil or similar around the injector nozzle at the connection on the intake pipe.

Gently work the fuel rail and injector nozzles loose

Fig 4: Identifying Oil Dipstick's Bracket

Courtesy of VOLVO CARS OF NORTH AMERICA.

Removing the intake manifold and gasket 

Remove 

• oil dipstick's bracket.
• the lower screws for the intake manifold a few turns.

Remove 

• the mounting screws in the upper row and the outer in the lower row.
• the intake manifold by lifting it approximately 20 mm 

  Allow the crankcase ventilation hose to run through the intake manifold without disconnecting it from the flame trap.