Contents: Removal ⇓ Installation ⇓
Removal
1. Relieve the pressure in the fuel system (see chapter 4).
2. Disconnect the negative cable from the battery.
Caution: If your vehicle has a theft-protected audio system, make sure you have the unlock code before disconnecting the battery.
3. Drink coolant (see chapter 1).
4. Remove the air intake duct. Disconnect the accelerator cable, hoses and electrical connectors from the throttle body. The throttle body does not interfere with the removal of the manifold and can be removed together with the throttle body.
5. Tag and disconnect all wire harnesses and hoses from the intake manifold.
6. Disconnect the electrical connectors from the injectors. Disconnect the fuel supply and return hoses from the fuel rail (see chapter 4). The intake manifold can be removed leaving the ramp and injectors in place.
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7. Disconnect the pipe and the gas recirculation valve from the manifold (see chapter 4).
8. Unscrew the bolts and remove the support bracket for the inlet of the lecturer's trench legs (figure 8.8).
9. Hold the manifold from above and unscrew the bolts and nuts that secure it (figure 8.9).
10. Remove the intake manifold.
Installation
11. Carefully scrape off any remaining old gasket and sealant from the manifold and cylinder head mounting surfaces. Wash the surfaces with solvent. If there were leaks from under the gasket, check that the mounting surface of the manifold is not warped. The flatness of the surface can be restored by grinding.
12. Install the manifold with a new gasket and secure it with bolts and nuts by hand.
13. Tighten the bolts and nuts to the specified torque in three to four steps in the sequence shown in the figure 8.13.
14. Install the remaining parts in the reverse order of removal.
15. Before starting the engine, make sure that the throttle drive operates without sticking.
16. Check the coolant level. Start the engine and check for coolant leaks or air intake.
17. Take the car for a short drive and make sure that all vehicle systems, including cruise control, are working properly.