Intake Manifold: Service and Repair

Intake Manifold Assembly

Service Repair No - 30.15.02

Removal
1. Drain cooling system.
2. Remove fuel rail.
3. Remove breather hose from RH rocker cover
4. Remove bolt securing coolant pipe brackets to RH rocker cover and collect nut.
5. Loosen clip and disconnect coolant return hose from inlet manifold.
6. Remove 4 bolts securing engine harness to inlet manifold.
7. Release 8 spark plug leads from guide clips and disconnect leads from spark plugs.





8. Remove 4 bolts securing RH rocker cover to cylinder head.





9. Remove RH rocker cover.
10. Remove and discard rocker cover gasket.
11. Remove screw securing dipstick tube to LH rocker cover.
12. Remove 4 bolts securing LH rocker cover to cylinder head.





13. Remove LH rocker cover.
14. Remove and discard rocker cover gasket.
15. Disconnect coolant temperature sensor multiplug.
16. Loosen clip and disconnect coolant return hose from inlet manifold.
17. Release coolant pipe bracket from manifold.
18. Loosen clip and remove plenum chamber coolant hose from inlet manifold.
19. Remove 12 bolts securing inlet manifold in the sequence shown.





20. With assistance, move engine harness aside and remove inlet manifold assembly.
21. Remove 2 bolts and clamps securing inlet manifold gasket to cylinder block.
22. Remove and discard gasket and gasket seals.

Installation
1. Ensure mating faces of inlet manifold and cylinder head are clean.
2. Apply a thin bead of Loctite Superflex (black) sealant to the 4 notches between the cylinder head and block.
3. Position new gasket seals ensuring ends engage correctly in notches.
4. Fit new inlet manifold gasket.
5. Position inlet manifold gasket clamps and fit bolts.

NOTE: Do not fully tighten bolts at this stage.

6. With assistance, move engine harness aside and fit inlet manifold.
7. Fit inlet manifold bolts and initially tighten in sequence to 10 Nm (7 ft. lbs.).

NOTE: When fitting inlet manifold bolts, tighten in reverse of removal sequence.

8. Tighten inlet manifold bolts in sequence to 51 Nm (38 lbf. ft).
9. Tighten gasket clamp bolts to 18 Nm (13 ft. lbs.).
10. Fit plenum chamber coolant hose to inlet manifold and secure with clip.
11. Secure coolant pipe bracket to inlet manifold.
12. Connect coolant return hose to inlet manifold and secure with clip.
13. Connect coolant temperature sensor multiplug.
14. Clean mating faces of LH rocker cover and cylinder head.
15. Fit new rocker cover gasket to LH rocker cover.
16. Fit rocker cover and gasket to cylinder head.
17. Fit rocker cover bolts, ensuring short bolts are fitted inboard, and tighten by diagonal selection to: Stage 1 - 4 Nm (3 lbf. ft). Stage 2 - 8 Nm (6 lbf. ft). Stage 3 - Re-torque to 8 Nm (6 ft. lbs.).

NOTE: This torque tightening sequence also applies to the RH rocker cover bolts.

18. Align dipstick tube to rocker cover and tighten screw.
19. Clean mating faces of RH rocker cover and cylinder head.
20. Fit new rocker cover gasket to RH rocker cover.
21. Fit rocker cover and gasket to cylinder head.
22. Tighten RH rocker cover bolts in sequence given for LH rocker cover bolts.
23. Connect spark plug leads to spark plugs and secure to guide clips.
24. Fit bolts securing engine harness to inlet manifold.
25. Connect coolant return hose to inlet manifold and secure with clip.
26. Fit nut and bolt securing coolant pipe bracket to RH rocker cover.
27. Connect breather hose to RH rocker cover.
28. Fit fuel rail.
29. Refill cooling system.