Removal Manifold

Removal Manifold

1. 37. Disconnect manifold heating hoses (x2).
2. 38. Disconnect throttle body multiplex and harness clip.
3. 39. Disconnect breather pipe quickfits (x2) from air cleaner duct.
4. 40. Disconnect air cleaner duct (clip x1).
5. 41. Disconnect EGR vacuum hose.
6. 42. Disconnect EGR pipe union and tie aside.
7. 43. Remove manifold bolts (x 10) (see Figure 1).

Figure 1

1. 44. Remove bolts (x2) bracket to manifold (rear).
2. 45. Move manifold (2x people) forward, remove bolt for purge line P-clip, remove manifold.
3. 46. Remove gaskets and clean mating faces.

Installation

Manifold to Vehicle

1. 1. Install new gaskets to cylinder block (glue in place).
2. 2. Install manifold (allowing access to install bolt for purge line P-clip).
3. 3. Install manifold bolts (x10) (torque and tightening sequence).
4. 4. Install bolts (x2) bracket to manifold (rear).
5. 5. Connect EGR pipe union.
6. 6. Connect EGR vacuum hose.
7. 7. Connect air cleaner duct (clip x1).
8. 8. Connect breather pipe quickfits (x2) to air cleaner duct.
9. 9. Connect throttle body multiplex and harness clip.
10. 10. Connect manifold heating hoses (x2).

Installation RH Side

1. 11. Connect EGR vacuum pipe to sensor and manifold.
2. 12. Install coolant pipe bracket (bolt x2, nut x2).
3. 13. Connect EGR (x1), fuel rail pressure sensor (x1) and injector multiplexes (x4).
4. 14. Refit (inj/alt) harness to coolant pipe bracket (fir tree x3).
5. 15. Connect heater hose to pipe (quick fit).
6. 16. Refit heater hose (clipx2) and EGR vacuum lines (clips x2) to bracket.
7. 17. Install fuel feed pipe.
8. 18. Install purge pipe P-clip.
9. 19. Install harness bracket to engine.

Installation LH Side

1. 31. Connect breather hose to manifold (quickfit).
2. 32. Connect IAT multiplex.
3. 33. Unclip injector harness from cam cover (x2).
4. 34. Connect injector multiplexes (x4).
5. 35. Install pipe support bracket (nuts x2, bolts x2).
6. 36. Install harness support bracket (bolt x1, nut x2) release harness clips (fir tree x3).
7. 37. Connect booster hose to manifold and support clip.
8. 38. Connect heater hose from pipe (quick fit).
9. 39. Install heater hose (x2) and throttle body hose (x2) from support bracket.
10. 40. Connect purge line to manifold and into support clip.
11. 41. Connect breather hoses (x2) to cam cover.
12. 42. Install coil cover.
13. 43. Install corner cross brace (torque bolts with vehicle on level ground).

Note: The installation is not handed

1. 44. Refill coolant (see Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
2. 45. Install cross brace. (torque bolts with vehicle on level ground).

Upper Intake Manifold Assembly Gasket (RHD) - Renew

Removal

1. 1. Depressurise fuel rail (see Workshop Manual procedure 10.01.EK Fuel System - Depressurise).
2. 2. Coolant drain (see Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
3. 3. Remove cross brace (bolts x4).

Removal RH Side

1. 4. Remove coil cover.
2. 5. Remove corner cross brace.

Removal Manifold

1. 20. Feed harness into inner wing area.
2. 21. Install fusebox to bracket.
3. 22. Install earth lead to fusebox.
4. 23. Install battery lead to fusebox (1x nut and rubber cover).
5. 24. Install multiplexes to fuse box.
6. 25. Install fusebox bracket fixings.
7. 26. Refit harness fir tree clips to cylinder head.
8. 27. Refit engine breather hose.
9. 28. Install VVT solenoid multiplex, position coil and CMP harness (1x edge clip).
10. 29. Install ECM (see Workshop Manual procedure 03.13.NC Module - Power Train Control - Renew).
11. 30. Install coil cover.