Gasket - Inlet Manifold - Upper - Without Secondary Air Injection

Gasket - Inlet Manifold - Upper - Without Secondary Air Injection

Service Repair No - 30.15.24

Remove

1. Release fixings and remove battery cover.
2. Disconnect battery earth lead.
3. Remove bonnet.




4. Release MAF sensor harness from clip.
5. Loosen clips securing air intake hose. Release and remove air intake hose.

NOTE: Pre 03 MY air intake hose illustrated.




6. Disconnect throttle and cruise control cables. Release cables from abutment bracket and position aside.




7. Disconnect EVAP pipe from inlet plenum.
8. Disconnect multiplug from throttle body.
9. Remove clip securing breather hose to throttle body and release breather hose.
10. Position a drain tray beneath the engine to collect coolant.




11. Release clips securing coolant hoses to throttle body and disconnect hoses.




12. Disconnect brake servo vacuum pipe from inlet plenum.
13. Disconnect breather hose from inlet plenum.
14. Remove bolt securing coolant rails.
15. Release engine harness from bulkhead clips and position aside.
16. Remove 4 bolts securing ignition coils and position ignition coils aside.




17. Release plug leads from upper manifold clips.
18. Disconnect multiplug from IACV.
19. Release and disconnect IACV hose.




20. Remove 6 bolts securing upper inlet manifold and remove upper inlet manifold.
21. Collect upper inlet manifold gasket.


Refit

1. Clean upper and lower inlet manifold mating faces, dowels and dowel holes.
2. Using a new gasket, position upper inlet manifold. Fit bolts and, working in a diagonal sequence, tighten to 22 Nm (16 ft. lbs.).
3. Connect hose and multiplug to TP sensor.
4. Connect hose and multiplug to IACV. Secure hose with clip.
5. Secure HT leads to upper inlet manifold.
6. Position ignition coils, fit bolts and tighten to 8 Nm (6 ft. lbs.).
7. Ensure clip under ignition coils is located on fuel pipe.
8. Secure engine harness in bulkhead clips.
9. Fit coolant rail bolt and tighten to 22 Nm (16 ft. lbs.).
10. Connect breather hose to inlet plenum.
11. Connect brake servo vacuum pipe to inlet plenum.
12. Connect EVAP pipe to inlet plenum.
13. Position coolant hoses to throttle body and secure hose clips.
14. Fit breather hose to throttle body and secure clip.
15. Connect multiplug to throttle body.
16. Connect throttle and cruise control cables and secure in throttle body cams.
17. Adjust throttle and cruise control cables.
18. Connect air intake hose and tighten clips. Secure harness to air intake hose.
19. Top-up cooling system.
20. Fit bonnet.
21. Connect battery earth lead.
22. Fit battery cover and secure with fixings.