Removing The Intake Manifold And Gasket

Disconnect the battery negative lead. First read Battery, disconnecting .

Fig 1: Charge Air Pipe Over The Engine

Courtesy of VOLVO CARS OF NORTH AMERICA.

Depressurize the fuel system acc. to:Fuel system pressure release .

Remove: 

• the charge air pipe over the engine
• the cover plate over the connectors from the injectors
• the fuel rail mounting screws. 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 fuel line quick-release connector. See: Fuel line, lock .

• Separate the throttle body (TB) connector
• Remove the plastic charge air pipe between the throttle body (TB) and the charge air cooler (CAC)
• Seal the openings. Mark up and remove the vacuum hoses from the intake manifold.

Remove: 

• the oil filler cap
• the cover over the ignition coils
• the hose from the flame trap to the cam cover at the terminal in the cam cover.

Fig 2: Identifying Intake Manifold And Screws

Courtesy of VOLVO CARS OF NORTH AMERICA.

• Disconnect the dip stick pipe
• Slacken off the lower screws for the intake manifold a few turns
• Remove the mounting screws in the upper row and the outer screws in the lower row
• Remove the intake manifold by lifting it approximately 20 mm 
• Remove the nipple for the water heated crankcase ventilation.

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