Removing and Installing Intake Manifold

Intake manifold removal, installation and gasket replacement






Battery
Disconnect, reconnect.

Mixture control unit with air guide housing
Remove, reinstall.

Coolant
Partly drain, refill. Service and Repair

Shaped hoses (26) for auxiliary air
Remove, reinstall.

Engine wiring harness
Lace out, lace in.

Engine longitudinal control shaft
Remove, reinstall.

Bracket (1) for injection valves
Remove, reinstall.

Bowden cable for automatic transmission
Disconnect, reconnect.

Bearing bracket for control
Remove, reinstall.

All vacuum connections
Remove, reinstall.

Exhaust gas recirculation line on exhaust gas recirculation valve
Disconnect, reconnect.

Mounting screws
Remove, refit. Tighten screws from inside to the outside.

Coolant hose (2)
Loosen.

Intake manifold upper and lower parts (10 and 18)
Remove, reinstall. Clean, check flange surfaces with straightedge, machine on straightening plate if required.

NOTE: Upon assembly ensure that no vacuum lines and electrical wires are jammed in.

Intake manifold gaskets (12)
Renew.

Engine control
Adjust.

Leaks
Check by running engine, check fuel lines for leaks. Check intake system, fuel distributor and injection valves for leaks by spraying with Iso-Octane.

Idle speed
Check, adjust.

NOTE: Gaskets with changed coating were temporarily installed between intake manifold and cylinder head.
Characteristics: Blue coating around the suction and idle speed ports

Production Breakpoint: January - August 1984:

Production Breakpoint: November 1986:

A hose fitting with bead is installed to prevent slipping of the vacuum line on the intake manifold.

Production Breakpoint: July 1987:

Improved sealing by means of gaskets made of different material.