Contents: Removal ⇊ Installation ⇊
Warning! Remember that gasoline is highly flammable! When servicing fuel system components, observe all applicable fire safety precautions. Do not smoke, do not approach work areas with open flames or unprotected portable equipment. Do not service the system in a room equipped with natural gas-fired heating devices (such as water heaters and clothes dryers) equipped with a pilot flame. Remember that gasoline is a carcinogen that can cause cancer. Avoid contact with exposed skin. Wear protective rubber gloves, and in case of accidental contact, wash your hands thoroughly with warm water and soap. Collect spilled fuel immediately and do not store rags soaked in fuel near open flames. Remember that the fuel system of fuel-injected models is constantly under pressure. Before disconnecting the fuel lines, release any residual pressure in the system (for more details, see Chapter Power and exhaust systems). Wear safety glasses when servicing fuel system components. Always keep a class B fire extinguisher on hand!
Removal
1. Release the pressure in the fuel system (see Chapter Power and exhaust systems), then disconnect the negative cable from the battery.
Warning! If the car stereo system is equipped with a security code, make sure you have the correct combination to activate the audio system before disconnecting the battery!
2. Drain the cooling system (see Chapter Settings and ongoing maintenance).
3. Disconnect the air intake duct from the air cleaner assembly (see Chapter Power and exhaust systems).
4. After clearly marking, disconnect all electrical wiring and vacuum lines that interfere with removal of the intake manifold.
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5. Disconnect the accelerator cable from the throttle body, gas cables and cruise control system (cruise control) (see Chapter Power and exhaust systems), - do not release the cables from the bracket, but only loosen the bolts that secure the latter.
6. Remove the thermostat housing from the intake manifold.
7. Disconnect the fuel supply and return lines from the fuel line (see Chapter Power and exhaust systems).
Attention! The pressure in the system must be released in advance (see paragraph 1)!
8. Working under the vehicle, remove the intake manifold support bracket, after separating the wiring harness from it.
9. Remove the mounting bolts and remove the intake manifold from the engine.
Note: The lower manifold can be removed with the air duct plenum (upper manifold) installed on it, but access to the mounting bolts will be greatly facilitated if the plenum is removed first.
Installation
1. Wipe the intake manifold mounting nuts with solvent, then dry them thoroughly (using compressed air if possible).
Caution! When using compressed air, do not forget to wear safety glasses!
2. Assess the flatness of the mating surfaces of the pipeline using a special gauge (a steel ruler placed on its edge) and a blade-type feeler gauge. Compare the measurement results with the requirements of the Specifications.
3. Before installing the EGR valve, clean it with a small brush and solvent, thoroughly removing all accumulated deposits.
4. Inspect the pipeline for cracks and signs of deformation. A defective pipeline must be either turned or replaced.
5. Check the condition of the pipeline fasteners (bolts/studs). Replace defective elements.
6. Scrape off any traces of old gasket material from the mating surfaces of the head and intake manifold, then wipe the surfaces with a rag soaked in acetone.
7. Having selected a new sealing gasket, install the pipeline in its regular place and secure it by tightening all nuts by hand. Acting in a strictly defined order, tighten the fasteners with the required force (see Specifications). If you removed the pressure chamber, reinstall it (don't forget to replace the sealing gasket).
8. Further installation is carried out in the reverse order of dismantling. Finally, do not forget to fill the cooling system (see Chapter Settings and ongoing maintenance).
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