Genuine Volvo V40 Intake Manifold

Volvo V40 Intake Manifold Parts and Q&A

• Intake Manifold
  8627356
  Q: How to remove and refit the components of the engine, including the intake manifold and fuel injectors except GDI engine on Volvo V40?

  A:

  In order to remove the components, disconnect the battery negative lead and slacken and withdraw the securing screws to lift the cover panel from the top of the engine. Next, remove the securing screw and remove the hose support bracket from the intake manifold, and finally remove the air inlet duct from the throttle housing. Disconnect the wiring plug from each fuel injector, and if necessary, remove the fuel rail cover to give you more room. Disconnect the vacuum hose to the pressure regulator on the underside of the fuel rail and then undo the two bolts holding the fuel rail to the intake manifold, pulling the rail upwards to release the injectors and placing it on top of the engine, taking care not to damage the injector tips. For turbo versions, unbolt and remove the engine bay front cover panel, and then release the turbocharger inlet ducting prior to removing the throttle housing. Unclip the wiring harness from the bracket between the alternator upper mounting and the intake manifold, unscrew the three bolts and remove the bracket. Undo the bolt holding the dipstick tube to the manifold, twist the tube off, and pull it upwards to clean it out of the engine block, pulling the O-ring seal at the bottom with it. Engage and lock the handbrake, secure the rear wheels with chocks, jack up the front end of the car and place it on axle stands. Working underneath the engine compartment, unscrew the securing bolts and remove the intake manifold support bracket. Loosen the lower manifold retaining bolts, about two or three turns and take out all the upper manifold bolts. Lift the manifold upwards, passing the crankcase ventilation hose through the ducts, if applicable, and remove it from the cylinder head, taking care that the gasket has not stuck to the face of the manifold. With the manifold removed, remove the lower bolts, and then remove the gasket. Remove remaining components on the manifold, if needed. For refitting, do the opposite of removal operations, with a new intake manifold gasket, new seals and O-rings for the fuel injectors and a new O-ring seal for the base of the dipstick tube. Coat the threads of the fuel rail securing screws with thread-locking fluid, locate the manifold gasket on the cylinder head and fit the lower manifold bolts a few turns before fitting the manifold in position. Remember to pass the crankcase ventilation hose up between the second and third manifold ducts, tighten the intake manifold bolts to the specified torque and refit and adjust the accelerator cable.
• Intake Manifold
  8631715
  Q: What steps are involved in removing and refitting the intake manifold for GDI engine on Volvo V40?

  A:

  The intake manifold on the GDI engine is the ports are located on the top of the cylinder head, and this would allow dirt and debris to enter the engine more easily as the manifold is removed, but it would be advisable to use compressed air to clean the area before removing the manifold and to plug the intake ports with suitable material once you have removed the manifold. Start by draining the cooling system, or leave alone if the coolant hoses to the throttle housing and EGA valve housing are still connected. Remove the air cleaner and intake duct and disconnect the evaporative emissions system hose(s) from the throttle housing. At the back of the manifold, disconnect the brake servo vacuum hose after releasing the spring-type clip, unbolt or unclip the mounting brackets holding the wiring harness in place and move the wiring harness away from the manifold. From underneath the car, remove two of the bolts that attach the EGR elbow, remove the wire connecting the oxygen sensor, and with early models, remove two bolts on the top of the manifold support bracket as well as one on the plastic resonance chamber, and later models have a smaller support bracket with four bolts. Disconnect the accelerator cable on early models, or on later models, disconnect the wiring plugs for the EVAP system control valve and EGA valve, unclipping the wiring from the manifold. Remove the bolts holding each of the ignition coils in place, noting the earth wires, and then disconnect the wiring plug from each coil and remove them carefully from the spark plugs, marking their position if desired. If not already done, disconnect the crankcase breather hose, and then remove the bolts holding the throttle housing and its mounting bracket. Finally, remove the nuts and bolts holding the intake manifold, taking care not to leave any wiring attached, and carefully lifting the manifold with the plastic resonance chamber, recovering for reassembly the gaskets using, during the recovery, to cover or plug the manifold ports to prevent dirt. If it is required, on early models, the resonance chamber can be removed by undoing two bolts. For refitting, reverse the removal operations, making sure to clean the mating surfaces and to use new intake manifold gaskets and make up the manifold nuts and bolts to the specified torque starting with the center bolt.