Intake manifold — removal and installation (Defender 2007+)

Removal

Warnings:

• Some fuel will inevitably spill during this operation. Make sure that all necessary precautions are taken to prevent fire and explosion.
• Do not carry or use a cell phone while working with or in the immediate vicinity of any fuel related components. There is a risk of ignition of flammable vapors. Failure to follow these instructions may result in injury.
• Do not smoke or carry a lighted cigarette or open flame of any type when working on or near fuel-related components. There is a risk of ignition of flammable vapors. Failure to follow these instructions may result in injury.
• If fuel gets into your eyes, rinse them with cold water or a special eye wash solution and seek medical attention immediately.
• Wash your hands thoroughly after handling fuel, as prolonged contact with the skin may cause irritation. If irritation occurs, seek medical attention.
• Do not perform any repairs to the fuel system while the engine is running. Fuel pressure in the system can reach 2000 bar. Failure to follow this instruction may result in injury.

CAUTION: Diesel fuel injection equipment is manufactured to very precise tolerances and very small clearances. Therefore, absolute cleanliness is required when working on these components. Be sure to insert new plugs into all open ports and lines. Failure to do so may result in dirt entering the fuel injection system.

1. Disconnect the ground wire from the battery.

For more information, refer to the chapter: Disconnecting and connecting the battery (414-01 Battery, Battery Mounting and Cables, General Procedures).



2. Using a vacuum cleaner, remove foreign material from the high-pressure fuel supply lines, fuel rails and high-pressure fuel pump.

For more information, refer to the chapter: Cleaning the fuel injection system components (303-04A Fuel Delivery and Controls - ID4 2.4L Diesel Engine, General Procedures).

3. Release the fuel line.



4.

CAUTION: Plug all openings. Use new caps.

Disconnect the fuel return line.



5. Disconnect the camshaft position (CMP) sensor electrical connector.



6. Disconnect the wiring harness clamp.





7. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.



8. Remove 2 bolts from the intake manifold.



9.

CAUTION: Plug all openings. Use new caps.

Remove the intake manifold. Remove 9 bolts.



10. Remove and discard the 9 intake manifold O-rings.

Installation

1.

NOTE: Clean the contact surfaces of the elements.

Install new intake manifold O-rings.

2.

NOTE: Remove and discard plugs.

Install the intake manifold in place. Tighten the bolts (tightening torque 15 Nm).



3. Tighten the bolts (tightening torque 10 Nm).



4. Connect the EGR valve electrical connector.



5. Connect the CMP sensor electrical connector. Secure the wiring harness.

6.

NOTE: Remove and discard plugs. Reconnect fuel return line.

7. Connect the fuel line.

8. Connect the ground wire to the battery.

For more information, refer to the chapter: Connecting the Battery (414-01 Battery, Battery Mounting and Cables, General Procedures).