Intake Manifold: Service and Repair

INTAKE MANIFOLD

Removing
1. Depressurize fuel system.
2. Disconnect the battery negative lead.
3. Release the hose clamp and remove the radiator hose to enable the cooling system to be partially drained, so that coolant level is below the thermostat housing, refit the hose and secure in position with the hose clamp.
4. Remove plenum chamber. Intake Air Plenum
5. Remove ram housing.

CAUTION: Place a protective cover over intake manifold openings to prevent the ingress of dirt.

6. Disconnect the electrical multiplugs to the fuel temperature thermistor (sensor) and injectors.
7. Remove 2 nuts and bolts securing fuel pressure regulator to fuel rail. Ease fuel pressure regulator out of rail. Seal end of fuel rail with plastic plugs to prevent ingress of dirt.

NOTE: The intake manifold can be removed from the cylinder block without removing the fuel rail and injectors.

8. Disconnect electrical leads from air conditioning engine coolant temperature sensor located on the thermostat elbow.
9. Disconnect electrical leads to engine coolant temperature transmitter (sensor) located at front of intake manifold.
10. Remove injector harnesses from behind fuel rail and lay to one side.




11. Release hose clamps securing 2 heater hoses to the rigid heater pipes at the front right hand rocker cover.
12. Remove 2 bolts securing rigid heater pipes to intake manifold and ease pipes out of hoses.
13. Lay heater pipe assembly to one side.

Loosening Sequence:

14. Remove 12 bolts securing intake manifold.
15. Remove inlet manifold.
16. Remove 2 gasket clamps from cylinder block.
17. Lift off gasket, remove gasket seals.
18. Remove sealing compound from around water passage openings of cylinder heads.


Refitting



19. Locate the NEW seals in position with their ends engaged in the notches formed between the cylinder heads and block.

20. Lightly apply 'Hylomar sealant around the outside of the water passage openings on the cylinder heads manifold gasket and intake manifold



21. Fit the manifold gasket with the word 'FRONT' to the front and the open bolt hole to the front right hand side.
22. Fit the gasket clamps but DO NOT fully tighten the bolts at this stage.
23. Locate the intake manifold onto the cylinder heads, clean the threads of the manifold securing bolts.
24. Fit all manifold bolts and tighten them a little at a time, evenly, alternate sides working from the centre outwards.

Tightening Sequence:

25. Tighten to 38 Nm (28 ft lb).
26. Tighten the gasket clamps to 18 Nm (14 ft lb).
27. Reverse remaining removal instructions.
28. Replenish the cooling system.
29. Start the engine, check for water and fuel leaks.