Withdrawal
1. Relieve pressure in the fuel supply system (see chapter 4, section 2).
2. Disconnect the wire from the negative battery terminal.
3. Remove the air intake and throttle body (see chapter 4, sections 12, 13).
4. Remove the fuel distribution tube and injectors (see chapter 4, section 13).
5. Remove heat shield from exhaust manifold bypass pipe (see section 9).
6. Disconnect control cables from their brackets (see chapter 4, section 9).
7. Remove the power steering pump mounting to the manifold (see chapter 10, section 19). Pay attention to the location of the fasteners, this will come in handy during assembly.
8. Loosen the generator and turn it to the side. Separate the generator from its mounting bracket (see chapter 5, section 13). Pay attention to the location of the fasteners for subsequent assembly.
9. Drain the coolant from the cooling system (see chapter 1, section 29).
10. Disconnect heater tubes and hoses from manifold.
11. Disconnect the bypass hose.
12. Tag and disconnect the fuel and vacuum hoses and all harness connectors on the manifold. When disconnecting the fuel hoses, wrap them with a rag so that fuel residues do not leak out. To prevent the penetration of contaminants, plug the nozzles with plugs.
13. Turn away fixing bolts of an inlet collector and remove a collector. Do not insert a lever between the manifold and the heads as this may damage the soft aluminum sealing surfaces.
14. If you are installing a new manifold, transfer all fasteners and sensors to it.
Installation
Note. The mating surfaces of the cylinder head, cylinder block and manifold must be perfectly clean before installing the manifold. There are solvents for removing gaskets; with their help it is convenient to remove the material of old gaskets adhering to the heads and manifold (since the collector is made of aluminum, scraping may damage its surfaces). When using a solvent, strictly follow the instructions printed on its packaging.
15. Use a scraper to remove residual seal and gasket material (see illustration), then clean the mating surfaces with lacquer thinner or acetone. If, when installing the manifold, traces of sealant or grease remain on the mating surfaces, oil leakage or air leakage may occur through these places. Use a vacuum cleaner to remove pieces of gasket material that may have fallen into the intake ports or pushrod recesses.
7.15. Remove any remaining gasket material, but be careful not to scratch the mating surfaces of the manifold and cylinder head
16. Drive the threads in the bolt holes with a tap of the appropriate size, then with a jet of compressed air (if there is a source) remove shavings from holes.
Attention! When using compressed air, wear protective goggles or a face shield!
17. If steel manifold gaskets are used, apply a thin, even coat of sealant such as K&W Copper Coat to both sides of the gaskets before placing them on the cylinder heads (or its equivalent). Apply a coat of RTV Sealant to the lips of the new seals between the manifold and block, then install the seals. Make sure the sharp end of the seal fits snugly on both the head and the block (see illustration).
7.17. Installing manifold and block seals: 1 - area to be sealed, 2 - seal
18. Carefully lower the manifold into place. Apply a coat of sealant to the threads of the mounting bolt and tighten the mounting bolts by hand.
19. Tighten the bolts in two steps, following the sequence shown in the illustration, until all of them are tightened to the required torque specified in subsection "Tightening torques" of this chapter.
7.19. Intake manifold bolt tightening sequence
20. Install other parts in reverse order.
21. Change oil and oil filter (see chapter 1, section 12), fill the cooling system (see chapter 1, section 29). Start the engine and check the system for oil leaks or air leaks.