XC90 2.5T AWD L5-2.5L Turbo VIN 59 B5254T2 (2003)
Intake Manifold Gasket: Service and Repair
Intake pipe/gasket, replacement
Note! Since the illustrations in this service information are used for different model years and/or models, some variation may occur. However,
the essential information is always correct.
Removing the intake manifold and gasket
Disconnect the battery negative lead. First read Battery, disconnecting See: Starting and Charging/Battery/Service and Repair/Procedures/Battery,
Depressurize the fuel system acc. to: Fuel system pressure release See: Cylinder Head Assembly/Fuel Pressure Release/Service and Repair/Fuel System
the charge air pipe over the engine
the cover plate over the connectors from the injectors
the fuel rail mounting screws. Spray universal oil or similar around the injector nozzle at the terminal on the intake manifold. Gently work the fuel
rail and injector nozzles loose. Separate the fuel line quick-release connector. See: Fuel line, lock See: Powertrain Management/Fuel Delivery and
Air Induction/Fuel Rail/Service and Repair.
Separate the throttle body (TB) connector
Remove the plastic charge air pipe between the throttle body (TB) and the charge air cooler (CAC)
Seal the openings. Mark up and remove the vacuum hoses from the intake manifold.
the oil filler cap
the cover over the ignition coils
the hose from the flame trap to the cam cover at the terminal in the cam cover.