Volvo 240/740/760/780/940/960 1990-1998

Intake Manifold

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REMOVAL & INSTALLATION



2.3L 4-Cylinder Engine
  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the air cleaner-to-throttle body hose.
  6.  
  7. If equipped, disconnect the cruise control cables and hoses.
  8.  
  9. Remove the PCV valve.
  10.  
  11. Disconnect the wiring and the fuel hose from the cold start injector. If necessary, remove the cold start injector.
  12.  
  13. Disconnect the wiring and the hoses at the auxiliary valve. If necessary, remove the auxiliary valve.
  14.  
  15. Remove the intake manifold brace.
  16.  
  17. Label and disconnect the vacuum hoses at the intake manifold.
  18.  
  19. Loosen the clamp for the rubber connecting pipe on the air-fuel control unit and remove the boot from the manifold.
  20.  
  21. Remove the manifold bolts and manifold.
  22.  

To install:
  1. Clean the gasket mating surfaces thoroughly.
  2.  
  3. Install the intake manifold, using new gaskets, and tighten the bolts to 15 ft. lbs. (20 Nm).
  4.  
  5. Install the intake manifold brace and the air-fuel control unit connecting pipe.
  6.  
  7. Install and connect the auxiliary valve, cold start injector using a new gasket, and the PCV valve.
  8.  
  9. Connect all vacuum hoses and electrical connectors.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Start the engine and bring it to normal operating temperature.
  14.  

2.8L 6-Cylinder Engine

See Figure 1

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the air cleaner-to-throttle body hose.
  6.  
  7. Drain the radiator coolant.
  8.  
  9. Remove the throttle cable from the pulley and bracket.
  10.  
  11. If equipped, disconnect the cruise control cables and hoses.
  12.  
  13. On automatic transmission vehicles, remove the throttle cable that is connected to the transmission.
  14.  
  15. Remove the EGR pipe from the EGR valve to the manifold.
  16.  
  17. Disconnect the EGR vacuum line.
  18.  
  19. Remove the PCV valve.
  20.  

Cover the oil cap opening with a rag to keep dirt out.

  1. Remove the front manifold bolts and remove the front section of the manifold.
  2.  
  3. Unplug the cold start connector, fuel line and injector.
  4.  
  5. Remove the pressure control regulator vacuum lines, fuel lines and the connector.
  6.  
  7. Remove the auxiliary valve and its necessary piping.
  8.  
  9. Unplug the electrical connections at the air fuel control unit.
  10.  
  11. Remove all 6 spark plug wires.
  12.  
  13. Remove all 6 injectors.
  14.  
  15. Move the wiring harness to the outside of the manifold.
  16.  
  17. Disconnect the vacuum hose at the distributor and the intake manifold.
  18.  
  19. Disconnect the heater hose at the intake manifold.
  20.  
  21. Disconnect the hose to the diverter valve.
  22.  
  23. Disconnect the vacuum hose to the power brake booster.
  24.  
  25. Disconnect the throttle cable link.
  26.  
  27. Disconnect the wires to the micro-switch.
  28.  
  29. Pull the wires away from the intake manifold.
  30.  
  31. Remove the fuel filter line and the return line.
  32.  
  33. Remove the air control unit.
  34.  
  35. Disconnect the vacuum hose from the throttle valve housing.
  36.  
  37. Remove the pipe and cold start injector assembly.
  38.  
  39. Remove the intake manifold from the vehicle.
  40.  

To install:
  1. Clean all gasket mating surfaces thoroughly.
  2.  
  3. Install the intake manifold using new gaskets and tighten the bolts to 7-11 ft. lbs. (10-15 Nm).
  4.  
  5. Install the cold start injector assembly using a new gasket, air control unit, fuel filter and return line, throttle cable, EGR valve, diverter valve, heater hose, injectors and spark plug wires.
  6.  
  7. Install all vacuum, fuel and coolant hoses previously removed.
  8.  
  9. Attach all electrical connections previously removed.
  10.  
  11. Fill the radiator with coolant and check the engine and transmission oil.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Start the engine and bring to operating temperature.
  16.  
  17. Bleed the cooling system.
  18.  
  19. Check for leaks.
  20.  



Click image to see an enlarged view

Fig. Fig. 1: Intake manifold assembly-2.8L 6-cylinder

2.9L 6-Cylinder Engine
  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery lead.
  4.  
  5. Remove the air cleaner-to-throttle body hose.
  6.  
  7. Remove the throttle pulley cover.
  8.  
  9. Disconnect and remove the throttle switch wiring, throttle cable and bracket, cruise control vacuum servo and vacuum hoses at throttle the housing.
  10.  
  11. Remove the injector cover plate and distribution manifold retaining bolts (3).
  12.  
  13. Disconnect the pressure regulator vacuum hose and fuel line bracket.
  14.  
  15. Carefully lift out the injector and distribution manifold assembly.
  16.  
  17. Remove the air preheater hose.
  18.  
  19. Remove the left and right side power stage connectors on the bottom of the manifold.
  20.  
  21. Remove the manifold bottom mounting.
  22.  
  23. Disconnect the brake servo hose and vacuum hoses under the manifold.
  24.  
  25. Cut away the clamps securing the rubber sleeves between the manifold sections, and lift out the outer manifold section.
  26.  
  27. Remove the upper bolts and loosen the lower bolts.
  28.  
  29. Remove the inner section of the manifold.
  30.  

To install:
  1. Install the inner section of the manifold, using a new gasket.
  2.  
  3. Install the rubber sleeves on the inner section and lubricate the free ends with petroleum jelly.
  4.  
  5. Install the mounting bolts and torque to 15 ft. lbs. (20 Nm).
  6.  
  7. Route the wiring between the second and third branches of the outer manifold section.
  8.  
  9. Place the manifold against the lower section and connect the crankcase ventilation hoses.
  10.  
  11. Insert the manifold branches in the rubber sleeves. Secure with new Oetiker clamps.
  12.  
  13. Tighten the manifold lower mounting.
  14.  
  15. Reconnect the vacuum hoses, brake servo hose, power stage connectors and air preheater hose.
  16.  
  17. Inspect the injector O-rings. Lubricate with petroleum jelly.
  18.  
  19. Reconnect the fuel pressure regulator vacuum hose.
  20.  
  21. Press the fuel distribution manifold into position.
  22.  
  23. Tighten the manifold retaining bolts to 15 ft. lbs. (20 Nm).
  24.  
  25. Reconnect the injector harnesses and EGR vacuum hoses.
  26.  
  27. Install the injector cover.
  28.  
  29. Install the throttle cable, throttle pulley cover and vacuum hoses (cruise control and throttle housing).
  30.  
  31. Install the cable bracket at the throttle pulley.
  32.  
  33. Reconnect the PCV, idling valve wiring, air hose, air mass meter and throttle housing connector.
  34.  
  35. Connect the negative battery lead.
  36.  
  37. Start the engine and check operation.
  38.  

2.3L and 2.4L 5-Cylinder Engines

See Figures 2, 3, 4, 5, 6 and 7

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the injector cover.
  6.  
  7. Unfasten the connectors and clips from the injectors.
  8.  
  9. Remove the two clips holding the fuel line.
  10.  
  11. Remove the distribution manifold mounting bolts.
  12.  
  13. Carefully remove the fuel rail with the fuel injectors by pulling upward evenly over the entire rail assembly to unseat the injector O-rings.
  14.  
  15. Disconnect the hose to the purge valve.
  16.  
  17. Carefully lay the distribution manifold and injectors on the engine.
  18.  


WARNING
Make sure that the injectors and needles are not damaged.

  1. Remove the throttle pulley cover.
  2.  
  3. Disconnect the throttle linkage from the pulley.
  4.  
  5. Disconnect the intake air hose to the throttle body.
  6.  
  7. Remove the multi-nipple.
  8.  
  9. Remove the EGR hose clamp on turbo models.
  10.  
  11. Remove the pressure line to turbo instrumentation/EGR valve control.
  12.  
  13. Disconnect the vacuum hose.
  14.  
  15. Disconnect the brake booster hose.
  16.  
  17. Loosen the dipstick bracket and intake manifold lower bracket bolt.
  18.  

If additional room is necessary, you may remove the electric cooling fan.

  1. Loosen the lower intake manifold bolts several turns.
  2.  

The lower intake manifold bolts are not through-bolts.

  1. Remove the upper intake manifold bolts.
  2.  
  3. Remove the intake manifold.
  4.  
  5. Make sure the mating surfaces of the cylinder head and intake manifold is clean.
  6.  

To install:
  1. If removed, install the throttle body with a new gasket.
  2.  
  3. Install a new intake gasket.
  4.  
  5. Install the intake manifold and upper bolts. Tighten all bolts from inside to outside to 15 ft. lbs. (20 Nm).
  6.  
  7. Install the EGR valve (if equipped) with a new gasket.
  8.  
  9. Install the throttle body with a new gasket.
  10.  
  11. Install the multi-nipple and connect the hoses.
  12.  
  13. Install the fuel distribution manifold.
  14.  
  15. Install the wiring and injector cover.
  16.  
  17. Install the remaining components.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Test run engine and check for leaks.
  22.  



Click image to see an enlarged view

Fig. Fig. 2: Label and remove the various vacuum lines from the intake manifold



Click image to see an enlarged view

Fig. Fig. 3: Some hoses are more easily removed from their sources than at the intake manifold



Click image to see an enlarged view

Fig. Fig. 4: Remove the retaining bolts ...



Click image to see an enlarged view

Fig. Fig. 5: ... and carefully lift the intake manifold from the cylinder head



Click image to see an enlarged view

Fig. Fig. 6: Remove the old intake gasket from the cylinder head and thoroughly clean the mating surfaces



Click image to see an enlarged view

Fig. Fig. 7: You can see the valves through the intake ports. Inspect the valves for carbon build-up while the intake manifold is off

 
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