Volvo Truck 2003-05

Intake Manifold

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Removal & Installation



6-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove:

    The battery negative lead
     
    plastic charge air pipe and hose to charge air cooler
     
    The intake pipe between the air cleaner and the turbocharger
     

  4.  
  5. Remove the intake pipe for the air cleaner housing from the connection above radiator. Twist the pipe up.
  6.  
  7. Drain the fuel line.
  8.  
  9. Remove:

    The protective cover over the injector connectors
     
    injector connectors
     
    The fuel rail mounting bolts
     

  10.  


NOTE
Handle the injectors carefully to avoid damaging the nozzles and needles.

  1. Spray universal oil or similar around the injector terminals on the intake manifold.
  2.  
  3. Gently work the fuel rail and injectors loose.
  4.  
  5. Detach the fuel line from the nozzle pipe by pressing the quick-release connector.
  6.  
  7. Remove:

    The dip stick pipe mounting at the intake manifold
     
    The nipple for the crankcase ventilation under the intake
     

  8.  
  9. disconnect the throttle body connector. Remove the plastic charge air pipe from the throttle body.
  10.  
  11. Remove the upper bolts.
  12.  
  13. Remove the outer bolts from the lower row.
  14.  
  15. Slacken off the remaining bolts.
  16.  
  17. Lift up and remove the intake manifold.
  18.  
  19. Remove the remaining bolts and gasket.
  20.  

To install:



Click image to see an enlarged view

Fig. Intake manifold-6-cylinder engine

Intake manifold-6-cylinder engine
  1. Transfer the throttle body with a new gasket. Tighten to 84 inch lbs. (10 Nm).
  2.  
  3. Ensure that the gasket faces are clean.
  4.  
  5. Install a new gasket with the two centermost bolts in the lower row.
  6.  
  7. Lower the intake over the 2 bolts.
  8.  
  9. Install the remaining bolts.
  10.  
  11. Tighten all bolts. Tighten to 15 ft. lbs. (20 Nm).
  12.  
  13. Connect the throttle body connector.
  14.  
  15. Install:

    The vacuum hoses according to the earlier markings
     
    The nipple for the crankcase ventilation under the intake manifold
     
    The dip stick mounting bolt to the intake manifold. Tighten to 18 ft. lbs. (25 Nm)
     
    The plastic charge air pipe between the throttle body and the charge air cooler
     

  16.  
  17. Lubricate the injector rings with petroleum jelly.
  18.  
  19. Hold the fuel rail. Press the fuel line quick-release connector together until it clicks.
  20.  
  21. Press down the fuel rail. Check that all injectors are correctly positioned.
  22.  
  23. Tighten the fuel rail to 84 inch lbs. (10 Nm). Use new bolts.
  24.  
  25. Connect all the connectors to the injectors.
  26.  
  27. Install the protective cover over the connectors to the nozzles.
  28.  
  29. Install:

    intake manifold between air cleaner and turbocharger
     
    plastic charge air pipe and hose to charge air cooler
     
    The air cleaner intake pipe
     
    The battery negative lead
     

  30.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove:

    The battery negative lead
     
    plastic charge air pipe and hose to charge air cooler
     
    The intake pipe between the air cleaner and the turbocharger
     

  4.  
  5. Remove the intake pipe for the air cleaner housing from the connection above radiator. Twist the pipe up.
  6.  
  7. Drain the fuel line.
  8.  
  9. Remove:
    NOTE
    Handle the injectors carefully to avoid damaging the nozzles and needles.



    The protective cover over the injector connectors
     
    injector connectors
     
    The fuel rail mounting bolts
     

  10.  
  11. Spray universal oil or similar around the injector terminals on the intake manifold.
  12.  
  13. Gently work the fuel rail and injectors loose.
  14.  
  15. Detach the fuel line from the nozzle pipe by pressing the quick-release connector.
  16.  
  17. Remove:

    The dip stick pipe mounting at the intake manifold
     
    The nipple for the crankcase ventilation under the intake
     

  18.  
  19. disconnect the throttle body connector. Remove the plastic charge air pipe from the throttle body.
  20.  
  21. Remove the upper bolts.
  22.  
  23. Remove the outer bolts from the lower row.
  24.  
  25. Slacken off the remaining bolts.
  26.  
  27. Lift up and remove the intake manifold.
  28.  
  29. Remove the remaining bolts and gasket.
  30.  

To install:

Click image to see an enlarged view

Fig. Intake manifold-6-cylinder engine

Intake manifold-6-cylinder engine

  1. Transfer the throttle body with a new gasket. Tighten to 88 inch lbs. (10 Nm).
  2.  
  3. Ensure that the gasket faces are clean.
  4.  
  5. Install a new gasket with the two centermost bolts in the lower row.
  6.  
  7. Lower the intake over the 2 bolts.
  8.  
  9. Install the remaining bolts.
  10.  
  11. Tighten all bolts. Tighten to 15 ft. lbs. (20 Nm).
  12.  
  13. Connect the throttle body connector.
  14.  
  15. Install:

    The vacuum hoses according to the earlier markings
     
    The nipple for the crankcase ventilation under the intake manifold
     
    The dip stick mounting bolt to the intake manifold. Tighten to 18 ft. lbs. (25 Nm)
     
    The plastic charge air pipe between the throttle body and the charge air cooler
     

  16.  
  17. Lubricate the injector rings with petroleum jelly.
  18.  
  19. Hold the fuel rail. Press the fuel line quick-release connector together until it clicks.
  20.  
  21. Press down the fuel rail. Check that all injectors are correctly positioned.
  22.  
  23. Tighten the fuel rail to 88 inch lbs. (10 Nm). Use new bolts.
  24.  
  25. Connect all the connectors to the injectors.
  26.  
  27. Install the protective cover over the connectors to the nozzles.
  28.  
  29. Install:

    intake manifold between air cleaner and turbocharger
     
    plastic charge air pipe and hose to charge air cooler
     
    The air cleaner intake pipe
     
    The battery negative lead
     

  30.  

8-Cylinder Engines
  1. Remove the 4 bolts at the suspension turrets
  2.  
  3. Remove the bolts of the upper engine mount on the engine.
  4.  
  5. Remove the upper cross stay.

    Click image to see an enlarged view

    Fig. Upper cross stay-8-cylinder engines

    Upper cross stay-8-cylinder engines
  6.  
  7. Remove the air cleaner cover by pulling it straight up.
  8.  
  9. Remove the 2 connectors from the engine control module (ECM); clip the band clamp to the cable harness.
  10.  
  11. Remove the connector from the mass air flow sensor.
  12.  
  13. Remove the brake vacuum hose from the vacuum pump.
  14.  
  15. Remove the 2 bolts of the fresh air hose in the front plate.
  16.  
  17. Remove the fresh air hose.
  18.  
  19. Remove the air cleaner by pulling it straight up.
  20.  
  21. Remove the upper engine covers by pulling them straight up.
  22.  
  23. Remove the cover over the servo pump.
  24.  
  25. Detach the connector of the pressure and temperature sensor.
  26.  
  27. Remove the 2 vacuum hoses of the check valve of the distribution damper.
    NOTE
    There is a guide sleeve on the upper mounting for the plate. This must be lifted slightly so that the panel can be slid forward.

  28.  
  29. Remove the 6 bolts.
  30.  
  31. Lift and slide the protective plate forward.
  32.  
  33. Remove the protective plate.
  34.  
  35. Open the cock on the lower left edge of the radiator.
  36.  
  37. Drain the coolant into a clean receptacle.
  38.  
  39. Close the cock.
  40.  
  41. Install the protective plate.
  42.  
  43. Install the 6 bolts.
  44.  
  45. Lower the vehicle.

    Click image to see an enlarged view

    Fig. Upper engine mount-8-cylinder engine

    Upper engine mount-8-cylinder engine
  46.  
  47. Remove the 4 bolts and the upper engine mount.
  48.  
  49. Remove the brake vacuum hose from the intake manifold by releasing the clamp.
  50.  
  51. Remove the intake hose between the air cleaner and throttle body by releasing the 2 clamps.
  52.  
  53. Remove the 2 nuts on the throttle body.
  54.  
  55. Remove the 2 bolts on the throttle body.
  56.  
  57. Position aside the throttle body.
  58.  
  59. Detach the 2 coolant hoses, one from the throttle body and one from the coolant distribution pipe.
  60.  
  61. Remove the hose clip on the vacuum hose.
  62.  
  63. Remove the vacuum hose.
  64.  
  65. Remove the 2 M6 bolts on the non-return valve for crankcase ventilation
  66.  
  67. Remove the non-return valve for crankcase ventilation.
  68.  
  69. Remove the 21 bolts of the upper intake manifold.

    Click image to see an enlarged view

    Fig. Upper intake manifold bolts-V8 engine

    Upper intake manifold bolts-V8 engine
  70.  
  71. Remove the upper intake manifold. Discard the gaskets.
  72.  
  73. Drain the fuel system.
  74.  
  75. Remove the crankcase ventilation hose between the cylinder heads by releasing the 2 clamps.
  76.  
  77. Remove the 3 bolts from the fuel rail.
  78.  
  79. Remove the 2 bolts on the fuel pressure sensor.
  80.  
  81. Lift the fuel rail assembly with injector straight up and position it aside.

    Click image to see an enlarged view

    Fig. Lower intake manifold bolts-V8 engine

    Lower intake manifold bolts-V8 engine
  82.  
  83. Remove the 12 bolts and the lower intake manifold. Discard the gaskets.
  84.  

To install:

  1. Clean the gasket surfaces.
  2.  
  3. Install new gaskets.
  4.  
  5. Install the lower intake manifold. Tighten the 12 bolts to 14 ft. lbs. (19 Nm).
  6.  
  7. Lubricate the O-rings on the injectors with Vaseline or the like.
  8.  
  9. Install the fuel rail assembly with injectors.
  10.  
  11. Install the 3 bolts of the fuel rail.
  12.  
  13. Install the 2 bolts on the fuel pressure sensor.
  14.  
  15. Install the crankcase ventilation hose and 2 clamps.
  16.  
  17. Connect the fuel supply line and secure the line in the clamp.
    WARNING
    Make sure there is an audible click during connection.

  18.  
  19. Install new gaskets.
  20.  
  21. Install the upper intake manifold. Tighten the 21 bolts to 14 ft. lbs. (19 Nm).
  22.  
  23. Install the hoses to the intake manifold.
  24.  
  25. Install the non-return valve for crankcase ventilation.
  26.  
  27. Install the connector to the pressure and temperature sensor.
  28.  
  29. Install the 2 vacuum hoses of the check valve of the distribution damper.
  30.  
  31. Install the upper engine mount. Tighten the 4 M10 bolts.

    Click image to see an enlarged view

    Fig. Servo pump cover-V8 engine

    Servo pump cover-V8 engine
  32.  
  33. Install the cover over the servo pump
  34.  
  35. Position the engine covers and press them into the retainers.
  36.  
  37. Install the upper cross stay between the suspension turrets. Tighten the 4 bolts.
  38.  
  39. Install the bolt of the cross stay mount on the engine.
  40.  
  41. Install the air cleaner.
  42.  
  43. Install the brake vacuum hose on the brake pump.
  44.  
  45. Install the fresh air hose.
  46.  
  47. Install the 2 bolts of the fresh air hose in the front plate.
  48.  
  49. Install the 2 connectors to the engine control module (ECM).
  50.  
  51. Install the connector to the mass air flow sensor.
  52.  
  53. Install the band clamp on the cable harness in the air cleaner housing.
  54.  
  55. Install the cover over the air cleaner.
  56.  
  57. Fill with coolant.
  58.  
  59. Start the engine and allow it to warm to normal operating temperature. Check for leaks and proper function. Fill up fluids as necessary.
  60.  

5-Cylinder Engines
  1. Disconnect the battery negative lead.
  2.  
  3. Remove the fuel injection system.
  4.  
  5. Drain the fuel injection system.
  6.  
  7. Remove or disconnect:

    The charge air pipe over the engine
     
    The cover plate over the connectors from the injectors
     
    The fuel rail mounting bolts. Spray penetrating oil 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.
     
    Separate the throttle body connector
     
    The plastic charge air pipe between the throttle body and the charge air cooler
     
    Vacuum hoses from the intake manifold.
     
    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.
     
    The dip stick pipe
     

  8.  
  9. Slacken off the lower bolts for the intake manifold a few turns.
  10.  
  11. Remove the mounting bolts in the upper row and the outer bolts in the lower row.
  12.  
  13. Remove the intake manifold by lifting it approximately 3 / 4 inch (20mm).
  14.  
  15. Remove the nipple for the water heated crankcase ventilation.
  16.  
  17. Allow the crankcase ventilation hose to run through the intake manifold without disconnecting it from the flame trap.
  18.  
  19. Transfer components when replacing the intake manifold
  20.  
  21. Transfer the electronic throttle module. Use a new gasket.
  22.  

To install:

Click image to see an enlarged view

Fig. Intake manifold-5-cylinder engine

Intake manifold-5-cylinder engine

  1. Install or connect:

    A new gasket held in position by the lower bolts for the intake manifold. Do not forget the clamp for the fuel line at the bolt in the lower row.
     
    The nipple for the water heated crankcase ventilation
     
    The intake manifold. Do not forget the crankcase ventilation hose. The hose must be inserted up through the gap between the second and third ducts
     
    The 3 upper bolts. Tighten all the bolts starting from the center to 14 ft. lbs. (19 Nm).
     
    The fuel rail. Press together the quick-release connector. Use new bolts.
     
    Injector connectors
     
    The protective cover over the fuel rail
     
    The vacuum hoses according to the earlier markings
     
    The plastic charge air pipe between the throttle body and the charge air cooler
     
    The connectors to the throttle body
     
    The dip stick in the intake manifold.
     

  2.  

 
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