Mercedes-Benz Cars 2000-05

Intake Manifold

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Engine ventilation tubes
     
    Electrical wiring, cables and hoses
     
    Manifold retaining bolts and manifold
     

  4.  

To install:

  1. Clean the gasket mating surfaces and install a new gasket.
  2.  
  3. Install or connect the following:

    Manifold and bolts. Torque bolts to 18 ft. lbs. (25 Nm), working from the middle outward.
     
    Electrical wiring, cables and hoses
     
    Engine ventilation tubes
     
    Negative battery cable
     

  4.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Cylinder head cover
     
    Mass Air Flow (MAF) sensor with the intake pipe
     

  4.  
  5. Properly relieve the fuel system pressure.

    Fuel rail with the injectors
     
    Vacuum lines from the intake manifold
     
    All electrical connections to the intake manifold
     
    Exhaust Gas Recirculation (EGR) valve
     
    Combination valve
     
    Intake manifold mounting bolts
     
    Intake manifold and gaskets
     

  6.  
  7. Place clean shop rags into the intake passages to prevent dirt from entering. Clean the gasket mating surfaces.
  8.  


    Click image to see an enlarged view

    Fig. Exploded view of the intake manifold and related components-3.2L and 3.7L engines shown; 4.3L and 5.0L similar


To install:

  1. Install the new gaskets and verify the secondary air injection passage opening in the gasket.
  2.  
  3. Remove the shop rags from the intake passages.
  4.  
  5. Install or connect the following:

    Intake manifold to the engine and tighten the mounting bolts to 15 ft. lbs. (20 Nm)
     
    Combination valve and tighten the bolts to 15 ft. lbs. (20 Nm)
     
    EGR valve
     
    Electrical connections to the intake manifold
     
    Vacuum lines to the manifold
     
    Fuel rail with the injectors
     
    MAF sensor with the air intake pipe
     
    Cylinder head cover and tighten the bolts to 88 inch lbs. (10 Nm)
     
    Negative battery cable
     

  6.  
  7. Read fault memory, encode the radio and normalize the power windows.
  8.  
  9. Start the vehicle and check for leaks.
  10.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Engine ventilation tubes
     
    Electrical wiring, cables and hoses
     
    Manifold retaining bolts and manifold.
     

  4.  

To install:

  1. Clean the gasket mating surfaces and install a new gasket.
  2.  
  3. Install or connect the following:

    Manifold and bolts. Torque bolts to 18 ft. lbs. (25 Nm), working from the middle outward
     
    Electrical wiring, cables and hoses
     
    Engine ventilation tubes
     
    Negative battery cable
     

  4.  

1.8L And 2.3L (111) Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Intake air cross pipe
     
    Ignition coils if necessary
     
    Power steering pump bracket mounting bolt, if necessary
     
    Fuel rail with injectors
     
    Intake manifold support bracket
     
    Vacuum, electrical and cable connectors
     
    Manifold mounting nuts and bolts
     
    Intake manifold
     

  6.  

To install:



Click image to see an enlarged view

Fig. Exploded view of the intake manifold mounting and related components-1.8L and 2.3L (111) engines

  1. Clean all gasket material from the sealing surfaces.
  2.  
  3. Install or connect the following:

    Manifold gaskets and intake manifold. Torque the mounting bolts and nuts to 15 ft. lbs. (20 Nm).
     
    Vacuum, electrical and cable connectors
     
    Intake manifold support bracket
     
    Fuel rail with new injector seals
     
    Power steering pump bracket mounting
     
    Ignition coils
     
    Intake air cross pipe
     

  4.  
  5. Check and adjust the throttle linkage.
  6.  
  7. Connect the negative battery cable, start the engine and check for leaks.
  8.  

2.2L And 2.3L (111) Engines
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Intake air cross pipe
     
    Ignition coils if necessary
     
    Power steering pump bracket mounting bolt if necessary
     
    Fuel rail with injectors
     
    Intake manifold support bracket
     
    Vacuum, electrical and cable connectors
     
    Manifold mounting nuts and bolts
     
    Intake manifold
     

  6.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the intake manifold mounting and related components-1997-00 2.2L and 2.3L (111) engines

  1. Clean all gasket material from the sealing surfaces. Install the manifold gaskets and intake manifold. Torque the mounting bolts and nuts to 15 ft. lbs. (20 Nm).
  2.  
  3. Install or connect the following:

    Vacuum, electrical and cable connectors
     
    Intake manifold support bracket
     
    Fuel rail with new injector seals
     
    Power steering pump bracket mounting
     
    Ignition coils
     
    Intake air cross pipe
     

  4.  
  5. Check and adjust the throttle linkage.
  6.  
  7. Connect the negative battery cable, start the engine and check for leaks.
  8.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Intake air cross pipe
     
    Ignition coils if necessary
     
    Power steering pump bracket mounting bolt if necessary
     
    Fuel rail with injectors
     
    Intake manifold support bracket
     
    Vacuum, electrical and cable connectors
     
    Manifold mounting nuts and bolts
     
    Intake manifold
     

  6.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the intake manifold mounting and related components-1997-00 2.2L and 2.3L (111) engines

  1. Clean all gasket material from the sealing surfaces. Install the manifold gaskets and intake manifold. Torque the mounting bolts and nuts to 15 ft. lbs. (20 Nm).
  2.  
  3. Install or connect the following:

    Vacuum, electrical and cable connectors
     
    Intake manifold support bracket
     
    Fuel rail with new injector seals
     
    Power steering pump bracket mounting
     
    Ignition coils
     
    Intake air cross pipe
     

  4.  
  5. Check and adjust the throttle linkage.
  6.  
  7. Connect the negative battery cable, start the engine and check for leaks.
  8.  

2.6L, 2.8L And 3.2L (112) And 4.3L, 5.0L And 5.5L (113) Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:Exploded view of the intake manifold mounting and related components-2.6L, 2.8L and 3.2L (112) shown; 4.3L, 5.0L and 5.5L (113) engines similarTo install:

    Negative battery cable
     
    Cylinder head cover
     
    Mass Air Flow (MAF) sensor with intake pipe
     
    Fuel rail with injectors
     
    Vacuum, electrical and cable connectors
     
    Exhaust gas Recirculation (EGR) valve
     
    Combination valve
     
    Manifold mounting bolts
     
    Intake manifold
     

    1. Clean all gasket material from the sealing surfaces.
    2.  
    3. Install or connect the following:

      New intake manifold gasket. Verify the secondary air injection passage opening in the gasket and install the intake manifold. Torque the mounting bolts to 15 ft. lbs. (20 Nm).
       
      Combination valve. Torque the bolts to 15 ft. lbs. (20 Nm).
       
      EGR valve
       
      Vacuum, electrical and cable connectors
       
      Fuel rail with new injector seals
       
      MAF sensor with the air intake pipe
       
      Cylinder head cover. Torque the bolts to 88 inch lbs. (10 Nm).
       

    4.  
    5. Reconnect the negative battery cable, start the vehicle and check for leaks.
    6.  

  6.  

2.8L 3.2L And 3.6L (104) Engines
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Vacuum, electrical and cable connectors
     
    Fuel rail with the injectors
     
    Resonance intake manifold (throttle body). Clean the gasket surfaces
     
    Intake manifold
     

  6.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the intake manifold mounting and related components-2.8L, 3.2L and 3.6L (104) engines

  1. Clean all gasket material from the sealing surfaces. Install intake manifold gaskets and manifold. Torque the mounting bolts to 18 ft. lbs. (25 Nm).
  2.  
  3. Install or connect the following:

    Resonance intake manifold with new gaskets
     
    Fuel rail with new injector seals
     
    Vacuum, electrical and cable connectors
     

  4.  
  5. Check and adjust the throttle linkage.
  6.  
  7. Connect the negative battery cable, start the engine and check for leaks.
  8.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Vacuum, electrical and cable connectors
     
    Fuel rail with the injectors
     
    Resonance intake manifold (throttle body). Clean the gasket surfaces
     
    Intake manifold
     

  6.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the intake manifold mounting and related components-2.8L, 3.2L and 3.6L (104) engines

  1. Clean all gasket material from the sealing surfaces. Install intake manifold gaskets and manifold. Torque the mounting bolts to 18 ft. lbs. (25 Nm).
  2.  
  3. Install or connect the following:

    Resonance intake manifold with new gaskets
     
    Fuel rail with new injector seals
     
    Vacuum, electrical and cable connectors
     

  4.  
  5. Check and adjust the throttle linkage.
  6.  
  7. Connect the negative battery cable, start the engine and check for leaks.
  8.  

3.2L (104) Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Vacuum, electrical and cable connectors
     
    Fuel rail with the injectors
     
    Resonance intake manifold (throttle body). Clean the gasket surfaces.
     
    Intake manifold
     

  6.  

To install:



Click image to see an enlarged view

Fig. Exploded view of the intake manifold mounting and related components-3.2L (104) engines

  1. Clean all gasket material from the sealing surfaces.
  2.  
  3. Install or connect the following:

    Intake manifold gaskets and manifold. Torque the mounting bolts to 18 ft. lbs. (25 Nm).
     
    Resonance intake manifold with new gaskets
     
    Fuel rail with new injector seals
     
    Vacuum, electrical and cable connectors
     

  4.  
  5. Check and adjust the throttle linkage.
  6.  
  7. Connect the negative battery cable, start the engine and check for leaks.
  8.  

3.2L (112) And 4.3L (113) Engines
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Cylinder head cover
     
    MAF sensor with intake pipe
     

  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Fuel rail with injectors
     
    Vacuum, electrical and cable connectors
     
    EGR valve
     
    Combination valve
     
    Manifold mounting bolts
     
    Intake manifold

    Click image to see an enlarged view

    Fig. Exploded view of the intake manifold mounting and related components-3.2L (112) engine shown.

     

  8.  

To install:

  1. Clean all gasket material from the sealing surfaces. Install the new intake manifold gasket. Verify the secondary air injection passage opening in the gasket and install the intake manifold. Torque the mounting bolts to 15 ft. lbs. (20 Nm).
  2.  
  3. Install or connect the following:

    Combination valve. Torque the bolts to 15 ft. lbs. (20 Nm)
     
    EGR valve
     
    Vacuum, electrical and cable connectors
     
    Fuel rail with new injector seals
     
    MAF sensor with the air intake pipe
     
    Cylinder head cover. Torque the bolts to 88 inch lbs. (10 Nm)
     

  4.  
  5. Reconnect the negative battery cable, start the vehicle and check for leaks.
  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Cylinder head cover
     
    MAF sensor with intake pipe
     

  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Fuel rail with injectors
     
    Vacuum, electrical and cable connectors
     
    EGR valve
     
    Combination valve
     
    Manifold mounting bolts
     
    Intake manifold

    Click image to see an enlarged view

    Fig. Exploded view of the intake manifold mounting and related components-3.2L (112) engine shown.

     

  8.  

To install:

  1. Clean all gasket material from the sealing surfaces. Install the new intake manifold gasket. Verify the secondary air injection passage opening in the gasket and install the intake manifold. Torque the mounting bolts to 15 ft. lbs. (20 Nm).
  2.  
  3. Install or connect the following:

    Combination valve. Torque the bolts to 15 ft. lbs. (20 Nm)
     
    EGR valve
     
    Vacuum, electrical and cable connectors
     
    Fuel rail with new injector seals
     
    MAF sensor with the air intake pipe
     
    Cylinder head cover. Torque the bolts to 88 inch lbs. (10 Nm)
     

  4.  
  5. Reconnect the negative battery cable, start the vehicle and check for leaks.
  6.  

4.2L And 5.0L (119) Engines


Click image to see an enlarged view

Fig. Exploded view of the intake manifold mounting and related components-4.2L and 5.0L (119) engines

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Partially drain the coolant.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner and engine cover
     
    Vacuum and electrical connectors
     
    Fuel supply (17/3) and return (17/2) lines
     
    Guide element (27)
     
    Throttle cable (30) at the control lever (9)
     
    Control pressure cable (98)
     
    Accelerator actuator (M16/1x1) connector and cable
     
    Coolant hose (33) at the front of the manifold
     
    Coolant hose at the rear of the manifold
     
    Manifold mounting bolts
     
    Intake manifold
     

  8.  

To install:



Click image to see an enlarged view

Fig. Intake manifold bolt tightening sequence-4.2L and 5.0L (119) engines

  1. Clean all gasket material from the sealing surfaces.
  2.  
  3. Install or connect the following:

    Manifold gasket and intake manifold. Torque the bolts in sequence to 18 ft. lbs. (25 Nm).
     
    Coolant hoses
     
    Accelerator actuator connector and cable
     
    Control pressure cable
     
    Throttle and transmission cables
     
    Guide element
     
    Fuel lines
     
    Vacuum, electrical and cable connectors
     
    Air cleaner and engine cover
     
    Engine oil
     
    Coolant
     
    Negative battery cable
     

  4.  



Click image to see an enlarged view

Fig. Exploded view of the intake manifold mounting and related components-4.2L and 5.0L (119) engines

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Partially drain the coolant.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner and engine cover
     
    Vacuum and electrical connectors
     

  6.  
  7. Properly relieve the fuel system pressure.
  8.  
  9. Remove or disconnect the following:

    Fuel supply (17/3) and return (17/2) lines
     
    Guide element (27)
     
    Throttle cable (30) at the control lever (9)
     
    Control pressure cable (98)
     
    Accelerator actuator (M16/1x1) connector and cable
     
    Coolant hose (33) at the front of the manifold
     
    Coolant hose at the rear of the manifold
     
    Manifold mounting bolts
     
    Intake manifold
     

  10.  

To install:

  1. Clean all gasket material from the sealing surfaces.
  2.  
  3. Install or connect the following:

    Manifold gasket and intake manifold. Torque the bolts in sequence to 18 ft. lbs. (25 Nm).
     
    Coolant hoses
     
    Accelerator actuator connector and cable
     
    Control pressure cable
     
    Throttle and transmission cables
     
    Guide element
     
    Fuel lines
     
    Vacuum, electrical and cable connectors
     
    Air cleaner and engine cover
     
    Engine oil
     
    Coolant
     
    Negative battery cable
     

  4.  



Click image to see an enlarged view

Fig. Exploded view of the intake manifold mounting and related components-4.2L and 5.0L (119) engines

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Partially drain the coolant.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner and engine cover
     
    Vacuum and electrical connectors
     

  6.  
  7. Properly relieve the fuel system pressure.
  8.  
  9. Remove or disconnect the following:

    Fuel supply (17/3) and return (17/2) lines
     
    Guide element (27)
     
    Throttle cable (30) at the control lever (9)
     
    Control pressure cable (98)
     
    Accelerator actuator (M16/1x1) connector and cable
     
    Coolant hose (33) at the front of the manifold
     
    Coolant hose at the rear of the manifold
     
    Manifold mounting bolts
     
    Intake manifold
     

  10.  

To install:

  1. Clean all gasket material from the sealing surfaces.
  2.  
  3. Install or connect the following:

    Manifold gasket and intake manifold. Torque the bolts in sequence to 18 ft. lbs. (25 Nm).
     
    Coolant hoses
     
    Accelerator actuator connector and cable
     
    Control pressure cable
     
    Throttle and transmission cables
     
    Guide element
     
    Fuel lines
     
    Vacuum, electrical and cable connectors
     
    Air cleaner and engine cover
     
    Engine oil
     
    Coolant
     
    Negative battery cable
     

  4.  

6.0L (120) Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Partially drain the coolant.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner and engine cover
     
    Vacuum, electrical and cable connectors
     
    Fuel supply and return lines
     
    Electronic accelerator actuator
     
    Throttle body
     
    Air inlet plenum chamber, if equipped
     
    Manifold mounting bolts
     
    Intake manifold
     
    Intermediate flanges
     

  8.  


    Click image to see an enlarged view

    Fig. Exploded view of the intake manifold-6.0L (120) engines


To install:

  1. Replace the shaped rubber seals and install the intermediate flanges with new gaskets.
  2.  
  3. Clean all gasket material from the sealing surfaces.
  4.  
  5. Install or connect the following:

    Manifold gasket and intake manifold
     
    Air intake plenum chamber
     
    Throttle body
     
    Electronic accelerator actuator
     
    Fuel lines
     
    Vacuum, electrical and cable connectors
     
    Air cleaner and engine cover
     
    Engine oil
     
    Coolant
     
    Negative battery cable
     

  6.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Partially drain the coolant.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner and engine cover
     
    Vacuum, electrical and cable connectors
     

  6.  
  7. Properly relieve the fuel system pressure.
  8.  
  9. Remove or disconnect the following:

    Fuel supply and return lines
     
    Electronic accelerator actuator
     
    Throttle body
     
    Air inlet plenum chamber if equipped
     
    Manifold mounting bolts
     
    Intake manifold
     
    Intermediate flanges

    Click image to see an enlarged view

    Fig. Exploded view of the intake manifold-6.0L (120) engines

     

  10.  

To install:

  1. Replace the shaped rubber seals and install the intermediate flanges with new gaskets.
  2.  
  3. Clean all gasket material from the sealing surfaces.
  4.  
  5. Install or connect the following:

    Manifold gasket and intake manifold
     
    Air intake plenum chamber
     
    Throttle body
     
    Electronic accelerator actuator
     
    Fuel lines
     
    Vacuum, electrical and cable connectors
     
    Air cleaner and engine cover
     
    Engine oil
     
    Coolant
     
    Negative battery cable
     

  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Partially drain the coolant.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner and engine cover
     
    Vacuum, electrical and cable connectors
     

  6.  
  7. Properly relieve the fuel system pressure.
  8.  
  9. Remove or disconnect the following:

    Fuel supply and return lines
     
    Electronic accelerator actuator
     
    Throttle body
     
    Air inlet plenum chamber if equipped
     
    Manifold mounting bolts
     
    Intake manifold
     
    Intermediate flanges

    Click image to see an enlarged view

    Fig. Exploded view of the intake manifold-6.0L (120) engines

     

  10.  

To install:

  1. Replace the shaped rubber seals and install the intermediate flanges with new gaskets.
  2.  
  3. Clean all gasket material from the sealing surfaces.
  4.  
  5. Install or connect the following:

    Manifold gasket and intake manifold
     
    Air intake plenum chamber
     
    Throttle body
     
    Electronic accelerator actuator
     
    Fuel lines
     
    Vacuum, electrical and cable connectors
     
    Air cleaner and engine cover
     
    Engine oil
     
    Coolant
     
    Negative battery cable
     

  6.  

Diesel Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Engine ventilation tubes
     
    Electrical wiring, cables and hoses
     
    Manifold retaining bolts and manifold.
     

  4.  

To install:

  1. Clean the gasket mating surfaces and install a new gasket.
  2.  
  3. Install or connect the following:

    Manifold and bolts. Torque bolts to 18 ft. lbs. (25 Nm), working from the middle outward
     
    Electrical wiring, cables and hoses
     
    Engine ventilation tubes
     
    Negative battery cable
     

  4.  

M111 And M271 Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Intake air cross pipe
     
    Ignition coils if necessary for access
     
    Idle speed motor and throttle body, if necessary for access
     
    Power steering pump bracket mounting bolt, if necessary for access
     
    Fuel rail with injectors
     
    Intake manifold support bracket
     
    Vacuum, electrical and cable connectors
     
    Manifold mounting nuts and bolts
     
    Intake manifold
     

  6.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the intake manifold mounting and related components-M111 engines

  1. Clean all gasket material from the sealing surfaces.
  2.  
  3. Install or connect the following:

    Manifold gaskets and intake manifold. Torque the mounting bolts and nuts to 15 ft. lbs. (20 Nm) on M111 engines and 10 ft. lbs. (14 Nm) on M271 engines.
     
    Vacuum, electrical and cable connectors
     
    Intake manifold support bracket
     
    Fuel rail with new injector seals
     
    Power steering pump bracket mounting
     
    Ignition coils
     
    Intake air cross pipe
     

  4.  
  5. Check and adjust the throttle linkage.
  6.  
  7. Connect the negative battery cable, start the engine and check for leaks.
  8.  

M112 And M113 Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Cylinder head cover
     
    Mass Air Flow (MAF) sensor with intake pipe
     
    Fuel rail with injectors
     
    Vacuum, electrical and cable connectors
     
    Exhaust gas Recirculation (EGR) valve
     
    Combination valve
     
    Manifold mounting bolts
     
    Intake manifold

    Click image to see an enlarged view

    Fig. Exploded view of the intake manifold mounting and related components-M112 shown, M113 similar

     

  6.  
  7. Place clean shop rags into the intake passages to prevent dirt from entering.
  8.  

To install:

  1. Clean all gasket material from the sealing surfaces.
  2.  
  3. Install or connect the following:

    New intake manifold gasket. Verify the secondary air injection passage opening in the gasket and install the intake manifold. Torque the mounting bolts to 15 ft. lbs. (20 Nm).
     
    Combination valve. Torque the bolts to 15 ft. lbs. (20 Nm).
     
    EGR valve
     
    Vacuum, electrical and cable connectors
     
    Fuel rail with new injector seals
     
    MAF sensor with the air intake pipe
     
    Cylinder head cover. Torque the bolts to 88 inch lbs. (10 Nm).
     

  4.  
  5. Reconnect the negative battery cable, start the vehicle and check for leaks.
  6.  

M272 Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove the engine cover, the remove the bolts securing the engine control module and place aside.
  6.  
  7. Remove the Mass Air Flow (MAF) sensor with intake pipe.
  8.  
  9. Disconnect the fuel feed line.
  10.  
  11. Label and detach all vacuum, electrical and cable connectors from the manifold.
  12.  
  13. Remove the manifold mounting bolts in the reverse order of tightening sequence.
  14.  
  15. Carefully lift the intake manifold, then detach the hoses from it.
  16.  
  17. Place clean shop rags into the intake passages to prevent dirt from entering.
  18.  
  19. Installation is the reverse of removal. Use new gaskets. Tighten the manifold bolts in sequence to 80 inch lbs. (9 Nm).

    Click image to see an enlarged view

    Fig. Intake manifold tightening sequence-M272 engine

  20.  

 
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