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Intake manifold

29.05.2026

This installations guide was created on the basis of the Volvo XC60 up to model year 2017. There may be deviations in the procedure for other vehicle models.


The following materials and tools are required to remove and install the intake manifold:
• Crowfoot spanner (1102582)
• Mounting hook (1057172)

Before starting work, the safety instructions for the diesel fuel system must be observed. The engine must be switched off and completely cooled down. The air filter housing and the air intake hoses must be removed as they cover access to the intake manifold. Then disconnect all connectors and fuel lines in the working area until the intake manifold is fully accessible.

Caution: The installation position of all lines and hoses should be documented before removal in order to facilitate subsequent installation. Open lines and connections must be sealed with plastic plugs (1078451) immediately after loosening to prevent the ingress of dirt.


Firstly, the air intake hose, which is on the throttle body, is removed. Special tool (1057172) is used for this. The hose is then completely removed and cleaned. 

Caution: The contact surfaces must be clean and free of foreign matter. It must also be ensured that the sealing ring is correctly positioned. This step is necessary to ensure a tight connection during subsequent installation.


In the next step, the intake manifold fastening screws are loosened and removed. The illustration shows the position of the screws. 
The following torques must be observed during subsequent installation: 
• Tightening torque M7 screws: 17 Nm
• Tightening torque M6 screws: 10 Nm
Once all fastenings have been loosened, the intake manifold can be carefully removed.

Now remove the throttle valve from the intake manifold. The illustration shows the four fastening screws. 
• Tightening torque for throttle valve (M5): 5 Nm

The boost pressure sensor and the associated mounting are removed from the old intake manifold and transferred to the new intake manifold. Ensure that the sensor is seated correctly and that the sealing surfaces are undamaged.


The control element of the swirl flap is now removed from the old intake manifold.


Ensure that the component is reinstalled in the correct position. 
• Tightening torque of the fastening screws (M5): 5 Nm
This step is crucial for the correct function of the swirl flap control.

Once all conversion work has been completed, the intake manifold is refitted. Installation is carried out in reverse order to removal. 
Note: The union nuts of the high-pressure fuel lines must be tightened in two steps using tool 1102582: 
• Step 1: 18 Nm 
• Step 2: 30 Nm
It is essential to ensure that the lines are tightened without tension.
After complete installation, check that all lines, plug connections and screws are correctly fitted and tightened. The engine should then be started and checked for leaks, particularly in the area of the fuel lines and sealing surfaces. Only when no leaks or malfunctions are detected is the work complete.
  • All notes serve only as an example and do not replace the workshop instructions of the automobile manufacturers! All information is supplied without guarantee!

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