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Intake Manifold Replacement
 
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Pelican Technical Article:

Intake Manifold Replacement

Nick Czerula

Time:

4 hours4 hrs

Tab:

$250

Talent:

*****

Tools:

Sockets 10, 12mm), wrenches, screwdrivers, fuel line tool

Applicable Models:

Volvo V70 (1998-01)
Volvo V70 2.4T (2001)
Volvo V70 AWD (1998-99)
Volvo V70 GLT (1998-00)
Volvo V70 GLT SE (2000)
Volvo V70 R (1998)
Volvo V70 R AWD (1999-00)
Volvo V70 T5 (1998-01)
Volvo V70 X/C (2001)
Volvo V70 X/C AWD (1998-00)
Volvo V70 X/C AWD SE (2000)

Parts Required:

Intake manifold gasket

Hot Tip:

Work with a cool engine

Performance Gain:

Repair vacuum leaks from old gaskets

Complementary Modification:

Replace crankcase breather (flame trap)

On the normally-aspirated 5-cylinder engine installed in Volvo V70 vehicles, the molded aluminum intake manifold is configured as one plenum with five runners. The manifold is sealed to the engine using a solid paper gasket.

If you have a hard-to-find vacuum leak, replace your intake manifold gaskets. If you find oil inside your intake manifold, replace the crankcase breather, also known as the flame trap. 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, knock sensors or flame trap.

It's a good idea to relieve the fuel system pressure before beginning. This will minimize the amount of fuel spilled. The best way to relieve fuel system pressure is to remove the fuel pump relay and run the vehicle until the engine stalls. See our tech article on fuel pump testing for the location of the fuel pump relay.

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. Questions or want to add to the article? Leave a comment below. When leaving a comment, please leave your vehicle information.

On the normally aspirated 5-cylinder engine installed in Volvo V70 vehicles, the molded aluminum intake manifold (red arrow) is configured as one plenum with five runners.
Figure 1

On the normally aspirated 5-cylinder engine installed in Volvo V70 vehicles, the molded aluminum intake manifold (red arrow) is configured as one plenum with five runners. The manifold is sealed to the engine using a solid paper gasket.

Working at the front of the intake manifold near the throttle housing, remove the vacuum line by pulling it straight off (red arrow).
Figure 2

Working at the front of the intake manifold near the throttle housing, remove the vacuum line by pulling it straight off (red arrow). Then slide the hose clamps down the hoses (green arrows) and remove the hoses. Then cut and remove the clamp (yellow arrow) and remove the final hose from the intake manifold.

Working at the intake air duct, loosen the hose clamps (red arrows).
Figure 3

Working at the intake air duct, loosen the hose clamps (red arrows). Then remove the air duct from the throttle housing and the intake air housing. Detach the hose at the bottom as you lift the duct up.

When removing the duct, detach the vent hose (red arrow) from the injector rail (green arrow).
Figure 4

When removing the duct, detach the vent hose (red arrow) from the injector rail (green arrow).

Using a flathead screwdriver and a rag, relieve the fuel rail pressure by pressing the Schrader valve in.
Figure 5

Using a flathead screwdriver and a rag, relieve the fuel rail pressure by pressing the Schrader valve in.

Using a fuel line release tool (5/16) (red arrows), release the fuel line (green arrow).
Figure 6

Using a fuel line release tool (5/16) (red arrows), release the fuel line (green arrow). Press the tool in toward the line to release the locks. Then slide the line off the fuel rail.

Remove the two 10mm fuel rail fasteners (red arrows).
Figure 7

Remove the two 10mm fuel rail fasteners (red arrows).

Then pull the fuel rail straight up and out of the intake manifold.
Figure 8

Then pull the fuel rail straight up and out of the intake manifold. Be careful not to damage a fuel injector when removing it. If the O-rings are stuck, you can lightly lever the fuel rail up using a flathead screwdriver. I like to lever between the edge of the valve cover and the fuel rail. Spray lubricant around the O-rings. This will make removing them much easier. If there is dirt in this area, remove it before spraying the lubricant.

Then place the fuel rail to the side (red arrow) out of the way.
Figure 9

Then place the fuel rail to the side (red arrow) out of the way.

Using a flat screwdriver, gently lever the fuel injector air shroud out at each port (inset).
Figure 10

Using a flat screwdriver, gently lever the fuel injector air shroud out at each port (inset). Work slowly so it doesn't break. Then remove it from the intake (red arrow).

Working at the center of the cylinder head, cut the hose clamp (red arrow) and remove the vent hose.
Figure 11

Working at the center of the cylinder head, cut the hose clamp (red arrow) and remove the vent hose.

Working at the engine oil dipstick, remove the 12mm fastener.
Figure 12

Working at the engine oil dipstick, remove the 12mm fastener. You will have to work upside down here (green arrow). The ratchet is shown attached to the fastener.

Remove the engine oil dipstick and tube from the engine.
Figure 13

Remove the engine oil dipstick and tube from the engine. Pull it straight up to remove it. Check that the sealing O-ring (green arrow) isn't stuck in the crankcase. If it is, remove it from the crankcase using a hook tool. Be careful not to push it into the engine when removing.

Now it is time to remove the intake manifold fasteners.
Figure 14

Now it is time to remove the intake manifold fasteners. Start by loosening the far right fastener (red arrow). I use a long extension with a 10mm universal socket. You can see the placement of my ratchet (green arrow). This fastener only has to be loosened, as the intake manifold has a slot to allow easy removal. This saves the trouble of accidentally dropping the fastener when reinstalling it.

Now remove the remaining fasteners.
Figure 15

Now remove the remaining fasteners. This photo shows the left side of the intake to the center. The right side has fasteners in a similar location. Remove the fasteners indicated by the red arrows. Loosen the lower fasteners (green arrow).

Working under the intake manifold, locate the manifold support.
Figure 16

Working under the intake manifold, locate the manifold support. Then remove the 12mm fastener (red arrow).

Lift the intake manifold enough to remove the crankcase breather hose (red arrow) and the fuel line (green arrow) through the plenum.
Figure 17

Lift the intake manifold enough to remove the crankcase breather hose (red arrow) and the fuel line (green arrow) through the plenum.

Then slightly lift it to gain access to the throttle housing electrical connector (red arrow).
Figure 18

Then slightly lift it to gain access to the throttle housing electrical connector (red arrow). It is mounted next to the starter motor. Press the release tab and pull the connector apart. Continue to lift the intake manifold off the cylinder head, disconnecting hoses and electrical connectors. 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 gasket (red arrow).
Figure 19

Before installing, replace the intake manifold gasket (red arrow). Remove it by pulling it straight off. If the gasket is stuck, scrape it off using a plastic gasket scraper. If you plan to replace your flame trap now is a good time. You have great access to it, and you can easily connect the hoses. See our tech article on flame trap (crankcase breather) replacing. Remove the items that 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. Reinstall the remaining items in the reverse order of removal. 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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