Replacing the intake manifold and gasket

Special tools:

NOTE: As the graphics in this service information are used for different model years and/or models, some variation may occur. However, the essential information in the graphics is always correct.

Preparation

Remove the front engine cover if applicable.

Disconnect the battery negative lead. First read Note when disconnecting and connecting the battery lead .

Drain the fuel injection system. See Draining the fuel injection system .

Removing the fuel rail

Fig 1: View Of Ignition Coils Cover, Crankcase Ventilation Hose, Throttle Body (TB) Cover, Nozzle Connectors/Cover & Fuel Pressure Regulator Vacuum Hose

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove:

the cover over the ignition coils
the crankcase ventilation hose from the top of the cam cover
the cover over the throttle body (TB)
the protective cover over the nozzle connectors
the connectors from the nozzles
the vacuum hose for the fuel pressure regulator from the throttle body (TB).

Removing fuel line

Fig 2: Removing/installing Fuel Line

Courtesy of VOLVO CARS OF NORTH AMERICA.

Disconnect the quick-release connector between the fuel line and the fuel rail. Use tool 9512666 .

Remove the mounting screws from the fuel rail.

Gently work the fuel rail and injector nozzles loose as a single unit.

Removing components

Fig 3: Removing/Installing Components

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove:

the hose from the assisted air control valve in the inlet hose
the intake hose between the mass air flow (MAF) sensor and throttle body (TB)
the vacuum hoses from the intake manifold
the throttle cable
the connectors from the assisted air control valve and throttle position (TP) switch
the screw from the cable duct mounting in the throttle body (TB)
the knock sensor (KS) cable from the clip
the brake servo hose
the bracket between the intake manifold and the pump
the screw holding the dip stick pipe to the intake manifold
the upper screw for the intake manifold support bracket, slacken the lower a few turns.

Removing the intake manifold

Fig 4: Removing/Installing Intake Manifold

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove:

the mounting screws for the intake manifold
the pipe screw and the nipple connection.

Transferring components when replacing the intake manifold

Transfer the throttle body (TB) and the assisted air control valve. Use new gaskets. Tighten to 10 Nm .

Installing the intake manifold and gasket

Fig 5: Removing/Installing Intake Manifold

Courtesy of VOLVO CARS OF NORTH AMERICA.

NOTE: Ensure that the gasket faces are clean.

Install:

a new gasket
the intake manifold. Do not forget the crankcase ventilation hose. The hose must be inserted up through the gap between the second and third ducts
the screws.

Tighten all the screws starting from the center. Tighten to 20 Nm .

Install and tighten the screws for the support bracket (under the intake manifold).

Install the hose and the pipe screw. Use a new gasket. Tighten to 26 Nm .

Installing components

Fig 6: Removing/Installing Components

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install:

the screw holding the dip stick pipe to the intake manifold
the bracket between the intake manifold and the pump
the brake servo hose
the cable for the knock sensor (KS)
the mounting screw for the cable duct in the throttle body (TB)
the connectors on the assisted air control valve and throttle position (TP) switch
the throttle cable
the vacuum hoses on the intake manifold
the intake hose between the mass air flow (MAF) sensor and throttle body (TB)
the hose from the assisted air control valve in the inlet hose.

Installing the fuel rail

Fig 7: Installing Fuel Rail With Injectors In Engine

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install:

the fuel rail and the injector nozzles. Press the quick-release connector together until it clicks. Use new screws . Tighten to 10 Nm
the vacuum hose for the fuel pressure regulator
the crankcase ventilation hose on the top of the cam cover. Use a new clamp
the connectors and protective cover for the injectors
the covers over the ignition coils and throttle body (TB).

Install the battery negative lead. First read Note when disconnecting and connecting the battery lead .

Final check

Test drive the car. Check the following:

that there is no fuel leakage
that the engine operates normally.

Clean the engine compartment. Check that everything is in position.

Install the front engine cover if applicable.

Special tools:

9512666

NOTE: As the graphics in this service information are used for different model years and/or models, some variation may occur. However, the essential information in the graphics is always correct.

Preparation

Remove the front engine cover if applicable.

Disconnect the battery negative lead. First read Note when disconnecting and connecting the battery lead .

Drain the fuel injection system. See Draining the fuel injection system .

Removing the fuel rail

Fig 1: View Of Ignition Coils Cover, Crankcase Ventilation Hose, Throttle Body (TB) Cover, Nozzle Connectors/Cover & Fuel Pressure Regulator Vacuum Hose

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove:

the cover over the ignition coils
the crankcase ventilation hose from the top of the cam cover
the cover over the throttle body (TB)
the protective cover over the nozzle connectors
the connectors from the nozzles
the vacuum hose for the fuel pressure regulator from the throttle body (TB).

Removing fuel line

Fig 2: Removing/installing Fuel Line

Courtesy of VOLVO CARS OF NORTH AMERICA.

Disconnect the quick-release connector between the fuel line and the fuel rail. Use tool 9512666 .

Remove the mounting screws from the fuel rail.

Gently work the fuel rail and injector nozzles loose as a single unit.

Removing components

Fig 3: Removing/Installing Components

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove:

the hose from the assisted air control valve in the inlet hose
the intake hose between the mass air flow (MAF) sensor and throttle body (TB)
the vacuum hoses from the intake manifold
the throttle cable
the connectors from the assisted air control valve and throttle position (TP) switch
the screw from the cable duct mounting in the throttle body (TB)
the knock sensor (KS) cable from the clip
the brake servo hose
the bracket between the intake manifold and the pump
the screw holding the dip stick pipe to the intake manifold
the upper screw for the intake manifold support bracket, slacken the lower a few turns.

Removing the intake manifold

Fig 4: Removing/Installing Intake Manifold

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove:

the mounting screws for the intake manifold
the intake manifold. Allow the crankcase ventilation hose to run through the intake manifold without disconnecting it from the flame trap
the two water hoses for the coolant and seal so that coolant vapor cannot seep out
the vacuum hose.

Transferring components when replacing the intake manifold

Transfer the throttle body (TB) and the assisted air control valve. Use new gaskets. Tighten to 10 Nm .

Installing the intake manifold and gasket

Fig 5: Removing/Installing Intake Manifold

Courtesy of VOLVO CARS OF NORTH AMERICA.

NOTE: Ensure that the gasket faces are clean.

Install:

a new gasket
the vacuum hose
the two heater hoses using a new G-clamp
the intake manifold. Do not forget the crankcase ventilation hose. The hose must be inserted up through the gap between the second and third ducts
the screws.

Tighten all the screws starting from the center. Tighten to 20 Nm .

Install and tighten the screws for the support bracket (under the intake manifold).

Installing components

Fig 6: Removing/Installing Components

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install:

the screw holding the dip stick pipe to the intake manifold
the bracket between the intake manifold and the pump
the brake servo hose
the cable for the knock sensor (KS)
the mounting screw for the cable duct in the throttle body (TB)
the connectors on the assisted air control valve and throttle position (TP) switch
the throttle cable
the vacuum hoses on the intake manifold
the intake hose between the mass air flow (MAF) sensor and throttle body (TB)
the hose from the assisted air control valve in the inlet hose.

Installing the fuel rail

Fig 7: Installing Fuel Rail With Injectors In Engine

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install:

the fuel rail and the injector nozzles. Press the quick-release connector together until it clicks. Use new screws . Tighten to 10 Nm
the vacuum hose for the fuel pressure regulator
the crankcase ventilation hose on the top of the cam cover. Use a new clamp
the connectors and protective cover for the injectors
the covers over the ignition coils and throttle body (TB).

Install the battery negative lead. First read Note when disconnecting and connecting the battery lead .

Final check

Test drive the car. Check the following:

that there is no fuel leakage
that the engine operates normally.

Clean the engine compartment. Check that everything is in position.

Install the front engine cover if applicable.