Intake Manifold
Intake Manifold
Special tools, testers and auxiliary items required
• Drift (T10060)
• Puller For Ignition Coil (T10095 A)
• Assembly tool (T10118)
Removing
• All cable ties which are opened or cut open when removing, must be replaced in the same position when installing.
Observe safety precautions when disconnecting the battery.
- Remove tool formed insert under luggage compartment floor covering.
- Remove cover - arrow - for battery compartment
- Remove formed insert from over battery.
- With ignition switched off, disconnect Battery Ground (GND) wire - arrow -.
- Remove center noise insulation fasteners - 1 to 3 -.
- Remove right noise insulation fasteners - 1 to 3 -.
- Disconnect vacuum hose - 2 - from air duct hose.
- Disconnect air guide hose - 1 - from Throttle Valve Control Module (J338).
- Disconnect Mass Air Flow (MAF) Sensor (G70) electrical connector - 3 -.
- Remove upper section of air filter housing - arrows -.
- Remove filter element.
- Remove air duct cover - 1 -.
- Unclip air duct - 2 -.
- Remove lower part of air duct - arrows -.
- Remove lower section of air filter housing - arrows -.
- Disconnect secondary air hose at position indicated by - arrow -.
- Free up air hose to Secondary Air Injection (AIR) pump.
- Separate electrical connectors - 2 - and - 3 -.
- Disconnect crankcase ventilation hose - 1 -.
- Remove throttle valve control module (J338) from intake manifold - arrows - and lay it aside.
- Disconnect electrical harness connectors to ignition coils, to do so attach assembly tool (T10118) on release button - arrow - and carefully disconnect harness connector.
- Attach Puller For Ignition Coil (T10095 A) on ignition coils - arrow - as depicted in the illustration and pull out ignition coils in succession.
- Remove ignition wiring harness strip and set it aside.
• Depending on the construction version, low pressure connectors were used in the version shown. To disconnect, slide back rubber cap - 1 - and slide release button - 2 - to the rear.
- Disconnect vacuum hoses - 2 through 5 - at rear of the intake manifold.
• Ignore - 1 -.
- Remove wiring connection from intake manifold - arrows - and lay back with hoses connected.
- Remove intake manifold bolts - arrows -.
- Remove top mounting bolts for fan shroud - top arrows -.
- Remove oil dipstick.
• Before removing ribbed belt, mark the turning direction on it with chalk or a felt tip pen. A reversed direction of rotation can cause damage to the belt under operating conditions.
- Swing tensioning device in direction of - arrow - to relieve tension on ribbed belt.
- Secure tensioner using drift (T10060) or using an angled hex socket head wrench.
- Remove ribbed belt.
- Free up coolant hose at bottom on fan shroud.
- Disconnect electrical harness connector - 3 - at Secondary Air Injection (AIR) Pump Motor (V101).
- Free up cable.
- Remove bracket - 2 - coolant pipe.
- Remove bolts - 1 -.
- Loosen bolt - 4 - and remove Secondary Air Injection (AIR) pump with bracket.
- Disconnect electrical harness connectors - 1 - for coolant fans at bottom on fan shroud.
- Remove mounting bolts for fan shroud at bottom - bottom arrows -.
- Pull out fan shroud downward with both fans.
- Disconnect electrical harness connector - 1 - for A/C clutch on A/C compressor and free up electrical wire.
The air conditioning refrigerant circuit must not be opened.
- Remove bolts - arrow - for A/C compressor.
- Securely tie A/C compressor with connected coolant hoses at front on the longitudinal member.
- Remove electrical wire - 1 - on generator.
- Separate electrical connector - 2 -.
• Ignore - 3 -.
- Remove upper idler roller - 1 -.
- Remove mounting bolts - 2 - and - 3 - for generator.
• Generator can be removed from bracket only with the upper mounting bolt still installed.
- Remove generator with electrical wiring connected from accessory assembly bracket.
- Remove generator downward and to the left.
- Disconnect electrical harness connector - arrow - at After-Run Coolant Pump (V51).
- Remove bolts - 1 to 5 - and remove accessory assembly bracket.
- Pull After-Run Coolant Pump (V51), with coolant hoses connected, downward out of rubber loops of retainer. Spray rubber loops with silicon-free lubricant if necessary.
• Coolant pump remains on the engine with coolant hoses connected.
- Disengage for Engine Speed (RPM) Sensor (G28) connector - arrow - from bracket on oil dipstick guide tube.
- Remove bolt - 3 - and remove oil dipstick guide tube - 2 -.
- Remove bolt - 4 - and remove vacuum reservoir - 1 - from intake manifold.
- Lay vacuum reservoir aside with lines connected.
- Remove bolts - arrows - at front of intake manifold.
- Disconnect vacuum line - arrow - from actuator for intake manifold change-over.
• Ignore - 1 - and - 2 -.
- Protect intake manifold from damage with a clean cloth - 1 -.
- Swing intake manifold forward - arrow 1 - and then pull slightly to left - arrow 2 -.
• Seal intake channel in cylinder head with clean cloth or foam pieces so that no small parts can fall in.
- Remove right fuel line bracket on cylinder head cover.
- Free up wiring harness - 1 - on cylinder head cover.
- Remove bolts - arrows -.
- Pull off fuel rail line - 2 - with fuel injectors from cylinder head and set aside with fuel line connected.
- Swivel intake manifold back into installation position and remove.
Installing
Installation is in reverse order of removal, noting the following:
• Replace seals.
• To assist installation of wiring harness - 1 - to fuel injectors, disconnect from fuel rail line.
- Install bracket for assemblies.
- Install generator.
- Install A/C compressor.
- Install fan shroud.
- Install Secondary Air Injection (AIR) pump.
- Install ribbed belt.
- Connect Ground (GND) cable to battery.
Tightening Specifications
