Good Morning -

Background:
In December, I purchased a 2006 X-Type Estate Wagon 3.0. When the vehicle was delivered, the Check Engine Light illuminated after about 5 miles of driving. Initially, thought it was the MAF. Changed the MAF out -- cleaning had no impact -- and the Check light went out for all of 5 minutes. Looking about the engine compartment, discovered the vacuum hose from the Fuel Pressure Sensor to the rear of the Inlet Manifold had failed. The hose end normally attached to the Fuel Pressure Sensor was hanging free; the nipple on the sensor where the hose attaches had broken off. Further, the hose itself was falling apart. For those, like myself, who may not know this vacuum hose is made up of two parts -- an inner small diameter (~3mm) red vacuum line, and an outer corrugated black covering that (I assume) is meant to protect the vacuum line. Anyway, the majority of the red line had turned white, and fell apart to the touch.

It was easy to locate a new Fuel Pressure Sensor; however, finding the vacuum hose was a bit harder. After a couple failed attempts at locating a hose replacement, I constructed a new hose using the original rubber fittings (still pliable and intact), correct-sized tubing, and a larger silicone hose to run the inner tube through. After all this effort, a part source identified an OEM vacuum hose still in its packaging so I snapped it up.

Moving Forward:
Now that the parts have been gathered, the hard part -- replacing the sensor and vacuum hose -- lies before me. Replacing the sensor, and attaching the vacuum hose to it requires access. And, access can only be obtained by disconnecting various hoses and electrical connections, and removing the Inlet Manifold. It's the removal of the Inlet Manifold that gives me pause. I've read the section on removing/installing the Inlet Manifold contained in the X-Type Manual (posted online) several times, and still have questions. It's a good manual but probably assumes a certain level of experience and expertise on the part of the user.

In addition to the X-Type Manual, I have read RobinGA's post of November 2016 on this very topic. great post, but he does not address replacing inlet manifold gaskets.

Since replacing engine gaskets is a new undertaking for me, a few questions:

1. It appears that a set of six gaskets (one for each cylinder?) is required. Correct?

2. It appears that the gaskets are not made of paper but some synthetic material. Do they require an application of any sealer or lubricant?

3. Besides the six gaskets, is there a larger gasket that fits along the perimeter of the inlet manifold sealing it to the cylinder head?

4. Upon removal, can I expect to find original paper gaskets? Vehicle has 53K miles, so the inlet manifold may have never been off..

5. Any advice for cleaning and scrapping manifold and cylinder head mating surfaces?

Finally, is this s task best left to a professional. Don't want to attempt correcting one problem only to create more.

Thank you, and kind regards,

 

I replaced that fuel pressure sensor on the injector rail twice, once to put in a replacement sensor and a second time to swap the old one back in when I found the new one didn't work but the old one checked out fine on a bench test. I did not remove the manifold at all. Going from memory here (which isn't what it once was) a 1/4" drive wrench with a couple of long extensions and a couple of universal/swivel adapters and it was fairly easy. Place your hand and the wrench between the battery and the coolant overflow bottle and thread the socket with extensions through all the hoses and wires. The top bolt was easy peasy. The bottom one difficult because you can't see it but as soon as you get your socket on there you are home free. You will need a grabber or a magnet because that bottom bolt will fall out of the socket.

Make certain you have no pressure in that fuel rail when you start. I would recommend using screwdrivers, bent pick tools, or similar to get the electrical connector off before removing the bolts and pulling the sensor out. I recall that part was easy. Put a little bit of lube on the O-rings when you put the new sensor in. No problems.

 

I will give it a try. Thank you.

 

I've replaced that tube and the only tight spot is getting your fingers in between the manifold nipple and the firewall.

 

I must replace the sensor because "...the nipple on the sensor where the hose attaches had broken off." so, a new sensor is required. Agree, it is possible (but tight) to remove the vacuum hose fitting from the back of the inlet manifold. That's how I removed the hose. Thank you.