Volvo Cars 1999-05

Intake Manifold

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Removal & Installation



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

    Negative battery cable
     
    Air intake assembly
     
    Front 6 bolts for upper intake manifold and 2 rear bolts
     
    EVAP canister hose
     
    Brake vacuum hose
     
    Throttle body (TB) connector
     
    Fuel pressure sensor connector
     
    Upper intake manifold
     
    Fuel injector connectors
     
    Fuel pressure sensor in fuel rail
     
    Fuel injectors and fuel rail as a unit
     
    Lower intake manifold mounting bolts
     
    Lower intake manifold
     

  6.  

To install:

  1. Install or connect the following:
    NOTE
    Route CCV hose up between cylinders 2 and 3.



    Lower intake manifold using a new gasket. Tighten 2 lower bolts to 14 ft. lbs. (19 Nm)
     



    Fuel rail with fuel injectors
     
    Fuel injector connectors
     
    Fuel pressure sensor connector
     
    Upper intake manifold with new gasket. Tighten 6 upper bolts starting with the center and working outward to 88 inch lbs. (10 Nm)
     
    EVAP canister hose
     
    Brake vacuum hose
     
    Air intake assembly
     
    Negative battery cable
     

  2.  
  3. Start engine and check for leaks.

    Click image to see an enlarged view

    Fig. Intake manifold six upper and two lower mounting bolts-2005-06 S40/V50/C70

    Intake manifold six upper and two lower mounting bolts-2005-06 S40/V50/C70
  4.  

4-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Ignition coil cover
     
    Crankcase ventilation hose
     
    Throttle body cover
     
    Injector connectors
     
    Throttle body vacuum hose
     
    Quick-release connector between the fuel line and the fuel rail using tool 951 2666 or equivalent.
     
    Fuel rail and injectors as a single unit
     
    Air intake hose
     
    Intake manifold vacuum hoses
     
    Throttle cable
     
    Assisted air control valve and throttle position (TP) switch connectors
     
    Brake servo hose
     
    Intake manifold support bracket
     
    Intake manifold
     

  6.  


    Click image to see an enlarged view

    Fig. 4-cylinder intake manifold bolts

    4-cylinder intake manifold bolts

To install:

  1. Install or connect the following:

    Intake manifold with new gasket. Tighten the bolts to 15 ft. lbs. (20 Nm).
     
    Intake manifold support bracket
     
    Brake servo hose
     
    Assisted air control valve and throttle position (TP) switch connectors
     
    Throttle cable
     
    Intake manifold vacuum hoses
     
    Air intake hose
     
    Fuel rail and injectors. Tighten fuel rail bolts to 7 ft. lbs. (10 Nm).
     
    Fuel line
     
    Throttle body vacuum hose
     
    Crankcase ventilation hose
     
    Injector connectors and protective cover
     
    Throttle body cover
     
    Ignition coil cover
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  

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

    Negative battery cable
     
    Ignition coil cover
     
    Crankcase ventilation hose
     
    Throttle body cover
     
    Injector connectors
     
    Throttle body vacuum hose
     
    Quick-release connector between the fuel line and the fuel rail using tool 951 2666 or equivalent.
     
    Fuel rail and injectors as a single unit
     
    Air intake hose
     
    Intake manifold vacuum hoses
     
    Throttle cable
     
    Assisted air control valve and throttle position (TP) switch connectors
     
    Brake servo hose
     
    Intake manifold support bracket
     
    Intake manifold

    Click image to see an enlarged view

    Fig. 4-cylinder intake manifold bolts

    4-cylinder intake manifold bolts
     

  6.  

To install:

  1. Install or connect the following:

    Intake manifold with new gasket. Tighten the bolts to 15 ft. lbs. (20 Nm).
     
    Intake manifold support bracket
     
    Brake servo hose
     
    Assisted air control valve and throttle position (TP) switch connectors
     
    Throttle cable
     
    Intake manifold vacuum hoses
     
    Air intake hose
     
    Fuel rail and injectors. Tighten fuel rail bolts to 88 inch lbs. (10 Nm).
     
    Fuel line
     
    Throttle body vacuum hose
     
    Crankcase ventilation hose
     
    Injector connectors and protective cover
     
    Throttle body cover
     
    Ignition coil cover
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  

6-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Charge air pipe, if equipped
     
    Charge air cooler (CAC) hose, if equipped
     
    Air intake hose
     
    Injector connectors
     
    Fuel rail and injectors as a single unit
     
    Quick-release connector between the fuel line and the fuel rail using tool 951 2666 or equivalent
     
    Dipstick tube bracket
     
    Crankcase ventilation hose
     
    Canister purge (CP) valve hose
     
    Engine cooling fan shroud, if equipped
     
    Engine cooling fan connector, if equipped
     
    Throttle body
     
    Intake manifold vacuum hoses
     
    Upper intake manifold bolts
     
    Outer intake manifold bolts from lower row
     

  6.  
  7. Slacken off the remaining bolts and remove the intake manifold.
  8.  
  9. Remove the remaining bolts and gasket.
  10.  

To install:

  1. Install or connect the following:

    Intake manifold with new gasket. Tighten bolts to 15 ft. lbs. (20 Nm).
     
    Throttle body, with new gasket.
     
    Intake manifold vacuum hoses
     
    Engine cooling fan connectors, if equipped
     
    Engine cooling fan shroud, if equipped
     
    Fuel rail and injectors. Tighten fuel rail bolts to 84 inch lbs. (10 Nm).
     
    Injector connectors
     
    CP valve hose
     
    Crankcase ventilation hose
     
    Dipstick tube bracket
     
    Air intake hose
     
    CAC hose, if equipped
     
    Charge air pipe, if equipped
     
    Negative battery cable
     

  2.  
  3. Start engine and check for leaks.
  4.  

  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
     
    Mass Air Flow (MAF) sensor connector
     
    Idle Air Control (IAC) valve connector and hose
     
    Air intake hose
     
    Throttle pulley cover
     
    Throttle Position (TP) sensor connector
     
    Accelerator cable and bracket
     
    Cruise control servo
     
    Throttle body vacuum hoses
     
    Injector cover
     

  4.  
  5. Install fuel injector holders on the injectors.

    Fuel pressure regulator vacuum hose
     
    Fuel supply manifold with injectors attached
     
    Air preheater hose
     
    Left and right power stage connectors
     
    Intake manifold bracket
     
    Brake booster vacuum line
     
    Positive Crankcase Ventilation (PCV) valve and hose
     
    Intake manifold outer section
     
    Intake manifold
     

  6.  

To install:

  1. Install or connect the following:

    Intake manifold with a new gasket and tighten the bolts to 15 ft. lbs. (20 Nm)
     
    Intake manifold outer section with new clamps
     
    PCV valve and hose
     
    Brake booster vacuum line
     
    Intake manifold bracket
     
    Left and right power stage connectors
     
    Air preheater hose
     
    Fuel supply manifold with injectors attached
     
    Fuel pressure regulator vacuum hose
     
    Injector cover
     
    Throttle body vacuum hoses
     
    Cruise control servo
     
    Accelerator cable and bracket
     
    TP sensor connector
     
    Throttle pulley cover
     
    Air intake hose
     
    IAC valve connector and hose
     
    MAF sensor connector
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  

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

    Negative battery cable
     
    Mass Air Flow (MAF) sensor connector
     
    Idle Air Control (IAC) valve connector and hose
     
    Air intake hose
     
    Throttle pulley cover
     
    Throttle Position (TP) sensor connector
     
    Accelerator cable and bracket
     
    Cruise control servo
     
    Throttle body vacuum hoses
     
    Injector cover
     

  4.  
  5. Install fuel injector holders on the injectors.

    Fuel pressure regulator vacuum hose
     
    Fuel supply manifold with injectors attached
     
    Air preheater hose
     
    Left and right power stage connectors
     
    Intake manifold bracket
     
    Brake booster vacuum line
     
    Positive Crankcase Ventilation (PCV) valve and hose
     
    Intake manifold outer section
     
    Intake manifold
     

  6.  

To install:

  1. Install or connect the following:

    Intake manifold with a new gasket and tighten the bolts to 15 ft. lbs. (20 Nm)
     
    Intake manifold outer section with new clamps
     
    PCV valve and hose
     
    Brake booster vacuum line
     
    Intake manifold bracket
     
    Left and right power stage connectors
     
    Air preheater hose
     
    Fuel supply manifold with injectors attached
     
    Fuel pressure regulator vacuum hose
     
    Injector cover
     
    Throttle body vacuum hoses
     
    Cruise control servo
     
    Accelerator cable and bracket
     
    TP sensor connector
     
    Throttle pulley cover
     
    Air intake hose
     
    IAC valve connector and hose
     
    MAF sensor connector
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  

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

    Negative battery cable
     
    Charge air pipe, if equipped
     
    Charge air cooler (CAC) hose, if equipped
     
    Air intake hose
     
    Injector connectors
     
    Fuel rail and injectors as a single unit
     
    Quick-release connector between the fuel line and the fuel rail using tool 951 2666 or equivalent
     
    Dipstick tube bracket
     
    Crankcase ventilation hose
     
    Canister purge (CP) valve hose
     
    Engine cooling fan shroud, if equipped
     
    Engine cooling fan connector, if equipped
     
    Throttle body
     
    Intake manifold vacuum hoses
     
    Upper intake manifold bolts
     
    Outer intake manifold bolts from lower row
     

  6.  
  7. Slacken off the remaining bolts and remove the intake manifold.
  8.  
  9. Remove the remaining bolts and gasket.
  10.  

To install:

  1. Install or connect the following:

    Intake manifold with new gasket. Tighten bolts to 15 ft. lbs. (20 Nm)
     
    Throttle body, with new gasket
     
    Intake manifold vacuum hoses
     
    Engine cooling fan connectors, if equipped
     
    Engine cooling fan shroud, if equipped
     
    Fuel rail and injectors. Tighten fuel rail bolts to 88 inch lbs. (10 Nm)
     
    Injector connectors
     
    CP valve hose
     
    Crankcase ventilation hose
     
    Dipstick tube bracket
     
    Air intake hose
     
    CAC hose, if equipped
     
    Charge air pipe, if equipped
     
    Negative battery cable
     

  2.  
  3. Start engine and check for leaks.
  4.  

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

    Negative battery cable
     
    Injector cover
     
    Accelerator cable
     

  4.  
  5. Install fuel injector holders on the injectors.

    Fuel pressure regulator vacuum hose
     
    Fuel supply manifold with injectors attached
     
    Throttle linkage
     
    Air intake hose
     
    Intake manifold vacuum lines
     
    Throttle pulley and bracket
     
    Idle Air Control (IAC) valve
     
    Exhaust Gas Recirculation (EGR) hose clamp, if equipped
     
    Boost pressure line, if equipped
     
    EGR regulator line, if equipped
     
    Brake booster vacuum line
     
    Dipstick tube bracket
     
    Intake manifold lower bracket
     
    Intake manifold
     

  6.  

To install:

  1. Install or connect the following:

    Intake manifold with a new gasket. Tighten the bolts to 15 ft. lbs. (20 Nm).
     
    Intake manifold lower bracket
     
    Dipstick tube bracket
     
    Brake booster vacuum line
     
    EGR regulator line, if equipped
     
    Boost pressure line, if equipped
     
    EGR hose clamp, if equipped
     
    IAC valve
     
    Throttle pulley and bracket
     
    Intake manifold vacuum lines
     
    Air intake hose
     
    Throttle linkage
     
    Fuel supply manifold with injectors attached and remove the injector holders
     
    Fuel pressure regulator vacuum hose
     
    Accelerator cable
     
    Injector cover
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  

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

    Negative battery cable
     
    Ignition coil cover
     
    Crankcase ventilation hose
     
    Air intake hose
     
    Injector connectors
     
    Charge air pipe, if equipped
     
    Quick-release connector between the fuel line and the fuel rail using tool 951 2666 or equivalent.
     
    Fuel rail and injectors as a single unit
     
    Intake manifold vacuum hoses
     
    Dipstick tube bracket
     
    Intake manifold support bracket
     
    Throttle body (TB) connector
     
    Intake manifold

    Click image to see an enlarged view

    Fig. Intake manifold-5-cylinder engine

    Intake manifold-5-cylinder engine
     

  6.  

To install:

  1. Install or connect the following:

    Intake manifold with new gasket. Tighten the bolts to 15 ft. lbs. (20 Nm).
     
    Intake manifold support bracket
     
    Fuel rail and injectors. Tighten fuel rail bolts to 88 inch lbs. (10 Nm).
     
    Injector connectors and protective cover
     
    Fuel line
     
    Crankcase ventilation hose
     
    Intake manifold vacuum hoses
     
    Charge air pipe, if equipped
     
    Air intake hose
     
    Ignition coil cover
     
    TB connector
     
    Dipstick tube bracket
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  

 
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