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Lower Intake Plenum Removal
 
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Pelican Technical Article:

Lower Intake Plenum Removal

Jared Fenton

Time:

3 hours3 hrs

Tab:

$30

Talent:

***

Tools:

10mm socket and extension, dykes, hose clamp crimper or flathead

Applicable Models:

Volvo C30 (2007-13)

Parts Required:

Intake plenum gasket, hose clamps

Hot Tip:

Use u-joints to access the mounting bolts

Complementary Modification:

Clean and/or replace fuel injectors

Removing the lower intake plenum is advantageous when removing the cylinder head on your Volvo C30 as well as gaining access to some of the components below the plenum on the front of the engine. In this article, I'll go over the steps involved with removing the plenum.

You'll first need to remove the upper intake plenum as well as the fuel injectors and fuel rail. See our articles on Upper Intake Plenum Removal and Fuel Injector Removal for more information.

Shown here are the three 10mm bolts (green arrows) along the top of the lower plenum to the cylinder head.
Figure 1

Shown here are the three 10mm bolts (green arrows) along the top of the lower plenum to the cylinder head. Loosen and remove the bolts using a long extension along with a u-joint.

Shown here are the relative positions of the three 10mm bolts (green arrows) along the bottom edge of the lower plenum.
Figure 2

Shown here are the relative positions of the three 10mm bolts (green arrows) along the bottom edge of the lower plenum. You'll have to feel for some of the bolts as they are difficult to see. Use an extension along with a u-joint to loosen and remove the bolts. Once free, carefully maneuver the plenum to access the hose connections.

Use a pair of dykes to cut the crimped end off the hose clamp (green arrow) holding the breather hose to the oil filter housing.
Figure 3

Use a pair of dykes to cut the crimped end off the hose clamp (green arrow) holding the breather hose to the oil filter housing. You'll need to pass this breather hose through the plenum once removed. This can be replaced with a regular screw type hose clamp upon reinstallation.

Shown here is the other breather hose connection going to the lower plenum.
Figure 4

Shown here is the other breather hose connection going to the lower plenum. Pull the upper end of the hose (green arrow) off the plenum.

Use a pair of dykes to cut the crimped end off the hose clamp (green arrow) holding the breather hose to the lower plenum.
Figure 5

Use a pair of dykes to cut the crimped end off the hose clamp (green arrow) holding the breather hose to the lower plenum. This is accessed through the left most intake runners. This can be replaced with a regular screw type hose clamp upon reinstallation.

Now carefully pass the oil breather hose (green arrow) through the hole in the plenum.
Figure 6

Now carefully pass the oil breather hose (green arrow) through the hole in the plenum. Remove the old plenum gasket from the cylinder head and take note of the orientation. You'll need the new gasket (part number 30650074) to line up the same way.

And here's the finished result with the lower plenum removed.
Figure 7

And here's the finished result with the lower plenum removed. I recommend stuffing clean shop rags or paper towels into each open port to keep dirt of debris out. Reinstallation of the lower plenum is the reverse of removal.


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