Contents: Removal ↡ Installation ↡
Removal
1. Disconnect the negative battery terminal.
2. Contact Chapter 1A and drain the coolant.
3. Remove the carburetor as described in paragraph 10.
4. Disconnect the brake booster vacuum hose from the manifold - unscrew the bypass bolt and remove the washers (see fig. 11.4).
Fig. 11.4. Disconnect the brake booster vacuum hose from the intake manifold
5. Disconnect the vacuum hoses from the crankcase emission control system, automatic transmission, central locking and exhaust gas recirculation system from the intake manifold (EGR, where it is installed). Write down the connection location of each hose to avoid confusion during assembly.
6. Loosen the clamps and remove the cooling hoses from the pipes on the intake manifold.
7. Where required, release the wiring harnesses from their holders. Disconnect the intake manifold heater wire plug from the connector - refer to Chapter 12.
8. Loosen the mounting bolts and remove the intake manifold mounting stand.
9. Where required, unscrew the bolts and remove the throttle linkage bracket from the cylinder head. Move it to the side.
10. Loosen the engine lifting bracket mounting bolt on the cylinder head (see fig. 11.10).
Fig. 11.10. Unscrew the bolt (shown by arrow) engine Lift Bracket Mounts
11. Loosen and remove the mounting nuts, then remove the engine lift bracket and intake manifold. Remove the gasket.
Installation
12. Thoroughly clean the mating surfaces of the cylinder head and inlet manifold - remove all traces of the old gasket. Be careful not to scratch or gouge the surfaces as this will cause shadows. Before proceeding further, check both surfaces for warpage using a metal ruler - for more information, refer to Chapter 2 Part G.
13. Position the new gasket on the cylinder head studs, then position the manifold into position.
14. The rest of the installation process is carried out in the reverse order of removal. Please note the following points:
- a) Tighten the manifold mounting nuts to the required torque.
- b) Fill the cooling system.
- c) Connect the wire plug to the collector heater.
- d) When finished, check and, if necessary, adjust the idle speed and CO content as described in Chapter 1A.