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Turbocharged Engine Intake Manifold Replacement
 
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Pelican Technical Article:

Turbocharged Engine Intake Manifold Replacement

Nick Czerula

Time:

3 hours3 hrs

Tab:

$250

Talent:

*****

Tools:

Set of sockets (8mm, 10mm, 13mm), wrenches, screwdrivers

Applicable Models:

R56 MINI Cooper S Hatchback (2007-11)

Parts Required:

Intake manifold gaskets

Hot Tip:

Work with a cool engine

Performance Gain:

Repair vacuum leaks from old gaskets

Complementary Modification:

Replace crankcase vent hoses

On the turbocharged 4-cylinder engine installed on MINI R56 vehicles, the molded plastic intake manifold is configured as one plenum with four runners. The manifold is sealed to the engine using molded runner profile gaskets.

If you have a hard-to-find vacuum leak, replace your intake manifold gaskets. If you find oil inside your intake manifold, replace the valve cover with the integrated crankcase breather. Clean the inside of the intake manifold thoroughly and be careful not to get any debris inside the cylinder head during the procedure. Removing the intake manifold will also give you easy access to the engine starter or coolant pipes and hoses.

Keep in mind that when your car was serviced before, parts may have been replaced with different size fasteners used in the replacement. The sizes of the nuts and bolts we give may be different from what you have, so be prepared with different size sockets and wrenches.

Protect your eyes, hands and body from fluids, dust and debris while working on your vehicle. If you're working with the electrical system, disconnect the battery before beginning. Always catch fluids in appropriate containers and properly dispose of any fluid waste. Recycle parts, packaging and fluids when possible. Do not work on your vehicle if you feel the task is beyond your ability.

Vehicle models change and evolve, as they grow older, so the vehicle shown in our illustrations may vary slightly from yours. If something seems different, let us know and share your info to help other users. Do you have questions or want to add to the article? Leave a comment below. When leaving a comment, please leave your vehicle information.

Remove the engine covers and microfilter housing. See our tech article on engine cover removing.

Start by detaching the breather hose at the valve cover.
Figure 1

Start by detaching the breather hose at the valve cover. Squeeze the collar (red arrow) and pull it off.

Working at the right corner of the intake air housing, remove the T20 Torx fastener (red arrow).
Figure 2

Working at the right corner of the intake air housing, remove the T20 Torx fastener (red arrow).

Move to the left side of the radiator support and remove the fresh air duct (red arrow).
Figure 3

Move to the left side of the radiator support and remove the fresh air duct (red arrow). It should be detached from the radiator support already, unclip it from the intake air housing and remove it.

Move to the left side of the intake air housing and unclip the vacuum line (red arrow).
Figure 4

Move to the left side of the intake air housing and unclip the vacuum line (red arrow). Then lift the intake air housing up and remove it from the engine.

Working at the mass airflow sensor, disconnect the electrical connector (red arrow).
Figure 5

Working at the mass airflow sensor, disconnect the electrical connector (red arrow).

Lift the intake air housing up, pulling it out of the rubber mounting grommets and remove it from the engine.
Figure 6

Lift the intake air housing up, pulling it out of the rubber mounting grommets and remove it from the engine.

Working at the center of the intake manifold near the firewall, remove the T20 Torx screw (red arrow).
Figure 7

Working at the center of the intake manifold near the firewall, remove the T20 Torx screw (red arrow).

Working at the center of the firewall, detach the duct from the lower cowl (red arrow).
Figure 8

Working at the center of the firewall, detach the duct from the lower cowl (red arrow).

Working at the right side duct, loosen the hose clamp (red arrow).
Figure 9

Working at the right side duct, loosen the hose clamp (red arrow). Then pull the small hose off the duct.

Remove the duct and vent (red arrow) from the engine.
Figure 10

Remove the duct and vent (red arrow) from the engine.

If needed, you can separate the right upper duct from the duct that runs to the throttle housing.
Figure 11

If needed, you can separate the right upper duct from the duct that runs to the throttle housing. I usually leave them together. To separate, lever out the retaining clip (red arrow) to the stop; then pull the ducts apart.

Working at the throttle housing, loosen the hose clamp (red arrows).
Figure 12

Working at the throttle housing, loosen the hose clamp (red arrows). Pull the duct off the throttle housing and remove it. Be careful to not lever on the throttle housing. R56 models have moved to plastic throttle housings. Any excessive pressure in the wrong spot can break them.

Working at the right rear corner of the intake manifold, remove the purge solenoid vacuum line by pressing the release tab (red arrows) and pulling the line straight off.
Figure 13

Working at the right rear corner of the intake manifold, remove the purge solenoid vacuum line by pressing the release tab (red arrows) and pulling the line straight off.

Working below the engine, through the opening in the sub frame (red arrow), remove the 10mm support bracket fastener (green arrow).
Figure 14

Working below the engine, through the opening in the sub frame (red arrow), remove the 10mm support bracket fastener (green arrow). The yellow arrow points to the throttle housing for orientation.

Working at the top of the intake manifold plenum, disconnect the manifold pressure sensor electrical connector (red arrow) by lifting the tab and pulling it straight off.
Figure 15

Working at the top of the intake manifold plenum, disconnect the manifold pressure sensor electrical connector (red arrow) by lifting the tab and pulling it straight off.

Next, remove the five 13mm manifold nuts (red arrows).
Figure 16

Next, remove the five 13mm manifold nuts (red arrows).

Slide the intake manifold away from the cylinder head just enough to access the wiring harness at the right side.
Figure 17

Slide the intake manifold away from the cylinder head just enough to access the wiring harness at the right side. Then detach the mounting clip (red arrow) from the manifold.

Slide the intake manifold away from the cylinder head enough to access the components beneath it (red arrow).
Figure 18

Slide the intake manifold away from the cylinder head enough to access the components beneath it (red arrow).

Slide the intake manifold away from the cylinder head until you can see the purge solenoid (red arrow).
Figure 19

Slide the intake manifold away from the cylinder head until you can see the purge solenoid (red arrow). Disconnect the electrical connector (green arrow) by lifting the tab and pulling it straight off.

Working at the left side of the intake, detach the wiring harness (red arrow) by pulling the clip out.
Figure 20

Working at the left side of the intake, detach the wiring harness (red arrow) by pulling the clip out. Then disconnect the throttle housing electrical connector (green arrow).

Slide the EPPC solenoid (red arrow) off the metal bracket (green arrow) and lay it aside.
Figure 21

Slide the EPPC solenoid (red arrow) off the metal bracket (green arrow) and lay it aside.

Working at the left side, detach the wiring harness mounting clip (red arrow) from the manifold.
Figure 22

Working at the left side, detach the wiring harness mounting clip (red arrow) from the manifold.

Working at the left side, detach the wiring harness mounting clip (red arrow) from the manifold.
Figure 23

Working at the left side, detach the wiring harness mounting clip (red arrow) from the manifold. Once the fasteners have been removed and the electrical and hose connections are detached, lift the intake manifold up and away from the cylinder head.

Continue to lift the intake manifold off the cylinder head, disconnecting hoses or electrical connectors you may have missed. Then remove the intake manifold from the engine. Once removed, seal the intake ports to prevent debris from entering the cylinder head.

Before installing, replace the intake manifold gaskets.
Figure 24

Before installing, replace the intake manifold gaskets. Remove them by prying the gaskets out with a small pick (red arrow) flathead screwdriver. Install the new gaskets by pressing them in (green arrow). Check that all gaskets are properly seated before installing the intake manifold. Remove items you used to seal the intake ports on the cylinder head. Then install the intake manifold to the cylinder head and tighten the fasteners in an alternating pattern. Double check the wiring harness routing and fuel line connections. Once complete, let the engine idle for about 10 minutes. If you left something disconnected or an item is misrouted, it is best to find out before driving.


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