Warning! Do not forget that gasoline is a highly flammable liquid! Observe all applicable fire safety precautions when servicing power system components. Non-smoking, do not approach the work area with an open flame or an uncovered carrier. Do not service the system in a room equipped with natural gas-fired, pilot flame-equipped heaters (such as water heaters and clothes dryers). Do not forget that gasoline is one of the carcinogens that contribute to the development of cancer -. try not to allow fuel to come into contact with open areas of the body. Use protective rubber gloves, in case of accidental unexpected contact, wash your hands thoroughly with warm water and soap. Clean up spilled fuel immediately and do not store fuel-soaked rags near open flames. Remember that the fuel injection system of models equipped with fuel injection is constantly under pressure. Relieve any residual pressure in the system before disconnecting fuel lines (see chapter Power and exhaust systems). Wear safety goggles when servicing power system components. Keep a class B fire extinguisher handy at all times!
Withdrawal
1. Relieve the pressure in the supply system (see chapter Power and exhaust systems), then disconnect the negative cable from the battery.
Attention! If the stereo system installed in the car is equipped with a security code, before disconnecting the battery, make sure that you have the correct combination to activate the audio system!
2. Empty the cooling system (see chapter Settings and ongoing maintenance).
3. Disconnect the intake duct from the air cleaner assembly (see chapter Power and exhaust systems).
4. Having clearly marked, disconnect all electrical wiring interfering with the dismantling of the inlet pipeline, as well as vacuum lines.
5. Disconnect the accelerator cable from the throttle body throttle and speed control cables (tempostat) (see chapter Power and exhaust systems), - do not release the cables from the bracket, but only give the bolts of the latter.
6. Remove the thermostat casing from the inlet pipeline.
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 relieved in advance (see paragraph 1)!
8. Working under the vehicle, remove the mounting bracket supporting the intake manifold after separating the wiring harness from it.
9. Turn out fixing bolts and remove the inlet pipeline from the engine.
Note. The lower pipeline can be removed together with the air path pressure chamber installed on it (upper pipeline), however, access to the mounting bolts will be greatly facilitated if the injection chamber is removed in advance.
Installation
1. Wipe the intake manifold nuts with solvent, then dry them thoroughly (using compressed air if possible).
Attention! Remember to wear protective goggles when using compressed air!
2. Evaluate the flatness of the mating surfaces of the pipeline using a special gauge (placed on the edge of a steel ruler) and a blade type probe. Compare the measurement results with the requirements of the Specifications.
3. Before installing the EGR valve, clean it with a small brush with solvent, carefully removing any accumulated deposits.
4. Inspect the pipeline for cracks and signs of deformation. A defective pipeline must be grooved or replaced.
5. Check the condition of the fasteners (bolts/studs) pipeline. Replace defective elements.
6. Scrape off any traces of the 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 picked up a new sealing gasket, install the pipeline in its regular place and secure it by tightening all the nuts by hand. Working in a strictly defined order, tighten the fasteners with the required force (see Specifications). If you removed the injection chamber, reinstall it (don't forget to replace the gasket).
8. Further installation is carried out in the reverse order of dismantling. In conclusion, do not forget to fill the cooling system (see chapter Settings and ongoing maintenance).