Intake Manifold/Gasket, Replacing: Preparation

Remove 

• the negative battery cable.

  First read Battery, disconnecting .

• the plastic charge air pipe and the hose of the charge air cooler.
• the intake manifold between the air cleaner and turbocharger.

Detach the air cleaner housing intake pipe from the connection above the radiator. Twist the pipe up.

Drain the fuel line. See Fuel system pressure release .

Remove 

• the cover over the injector connectors.
• the connectors from the injectors.
• the fuel rail mounting screws.

Open the fuel lines quick-release connector using tool 9512666 .

Spray universal oil or the like around the injectors' connection on the intake pipe.

Bend and carefully pull loose the fuel rail and injectors.

Remove 

• The canister purge (CP) valve from mounting on the fan shroud.
• the tie strap holding the wiring to the fan shroud.

Lift the hose for the expansion tank from the holders at the top edge of the fan shroud.

Disconnect both engine cooling fan connectors.

• the two screws holding fan shroud in place. Carefully lift engine cooling fan.

• the plastic charge air pipe between the charge air cooler and throttle body.

Unplug the throttle body connector.

• the dipstick tube's mounting at the intake manifold

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