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Upper Intake Plenum Removal
 
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Pelican Technical Article:

Upper Intake Plenum Removal

Jared Fenton

Time:

2 hours2 hrs

Tab:

$30

Talent:

***

Tools:

8mm socket and extensions, dykes, hose clamp crimping tool or

Applicable Models:

Volvo C30 (2007-13)

Parts Required:

Intake plenum gaskets, throttle body gasket, hose clamp

Complementary Modification:

Remove and clean fuel injectors

The Volvo C30 uses a two-piece intake plenum that houses the fuel injectors, fuel rail and throttle body. You'll need to remove the upper plenum in order to remove or replace the injectors and/or fuel rail. Removing the upper plenum is not difficult, although it does require removing a few items to gain access to the mounting bolts.

Begin by removing the throttle body and air filter housing. See our articles on Throttle Body Removal and Air Filter Housing for more information. You also need to disconnect the battery whenever you unplug the fuel injection computer (mounted on the air filter housing) from the car. See our article on Battery Replacement for more information.

Begin by disconnecting the vacuum hose on the right side of the upper plenum.
Figure 1

Begin by disconnecting the vacuum hose on the right side of the upper plenum. This is done by pressing the red collar (green arrow) in while pulling the hose (yellow arrow) out. It's a little tricky to get it to release if you haven't done it before.

Loosen and remove the six 8mm bolts (green arrows) holding the upper plenum to the lower plenum.
Figure 2

Loosen and remove the six 8mm bolts (green arrows) holding the upper plenum to the lower plenum. ThisPicture shows the relative position of the bolts which are accessed from below the plenum.

ThisPicture shows a better view of the bolts (green arrows).
Figure 3

ThisPicture shows a better view of the bolts (green arrows). Some of the bolts are a bit hard to see, so you'll have to feel for them. Work your way around the bottom until you can remove it from the lower plenum.

Pull the vacuum hose (green arrow) off the left side of the plenum.
Figure 4

Pull the vacuum hose (green arrow) off the left side of the plenum.

You'll now need to cut off the hose clamp (green arrow) off the vacuum hose and pull the hose off the upper plenum.
Figure 5

You'll now need to cut off the hose clamp (green arrow) off the vacuum hose and pull the hose off the upper plenum. Use a pair of dykes to cut through the crimped end. You can use a regular screw type clamp when re-installing the hose. It is a good idea to stuff clean shop rags or paper towels down each open plenum runner to prevent dirt or other small objects from falling in.

Shown here is the upper plenum removed from the car.
Figure 6

Shown here is the upper plenum removed from the car. Be sure to replace the five intake gaskets (part number 31331885, green arrows) as well as the throttle body gasket (part number 30637439, yellow arrow) when reinstalling the plenum. Simply pull the old gaskets out and press the new ones in. Installation is the reverse of removal.

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