Contents: Removal ↧ Installation ↧
Removal
1. Relieve the pressure in the fuel supply system (see chapter 4, section 2).
2. Disconnect the cable from the negative terminal of the battery.
3. Drain the coolant (see chapter 1, section 29).
4. Disconnect the upper radiator hose from the thermostat housing. If the intake manifold needs to be replaced, remove the thermostat (see chapter 3, section 3).
5. Disconnect the electrical connectors of the coolant temperature sensor and the exhaust gas recirculation (EGR) temperature switch (see chapter 6, sections 4 and 7).
6. If you are going to replace the intake manifold, remove the throttle body (see chapter 4, section 12); if you plan to reuse the intake manifold, there is no need to remove the throttle body.
7. If you are going to replace the intake manifold, remove the EGR valve (see chapter 6, section 7).
8. Remove the valve covers (see section 4).
9. Loosen the intake manifold mounting bolts (see illustration) and remove the manifold. Do not insert a lever between the manifold and heads as this may damage the soft aluminum sealing surfaces of the gasket. If you are installing a new manifold, transfer all parts and sensors to it.
5.9. The intake manifold is secured with nine bolts and two nuts (shown by arrows); the numerical sequence shown in the illustration is only valid for tightening the intake manifold bolts (nuts) during assembly - they should be loosened in the reverse order
10. Cut the old intake manifold gaskets as shown in the illustration; take them off.
5.10 To remove the old intake manifold gaskets (or install new ones), cut the old gaskets in places (shown by arrows) behind the bars, where they run in narrow strips behind the bars
Installation
Note: The mating surfaces of the cylinder head, cylinder block and manifold must be perfectly clean before installing the manifold.
11. Use a scraper to remove traces of sealing material and gaskets, then clean the mating surfaces with lacquer thinner or acetone. If traces of sealant or grease remain on the mating surfaces when the manifold is installed, oil leakage may occur through these areas. Use a vacuum cleaner to remove any gasket material that may have fallen into the intake ports or tappet recesses.
12. Clean the threads in the holes with a tap of the appropriate size, then remove the chips from the holes with a jet of compressed air.
Caution: When using compressed air, wear safety glasses or a shield to protect your eyes!
13. Apply a 3/16-inch (5 mm)drop of room-temperature vulcanizing RTV sealant to the front and rear cylinder block ridges running between the cylinder heads (see illustration).
5.13. Apply a drop of sealant to the edges between the cylinder heads (shown by arrows) or install seals on them
Note: Some gasket kits have face seals that can be used here in place of the sealant.
14. Cut new intake manifold gaskets in the same places where the old ones were cut and install them.
15. Carefully lower the manifold into place and tighten the bolts (nuts) by hand.
16. Tighten the bolts (nuts) in two stages, following the sequence shown in Illustration 5.9, until they are all tightened to the required torque specified in the "Tightening Torques" section of this chapter.
17. Install the remaining parts in reverse order.
18. Change the oil and oil filter, fill the cooling system (see chapter 1, sections 12 and 29). Start the engine and check the system for leaks.