Inlet manifold - r + r and replace seal

Operation 1072B10 · Inlet manifolds

Removing

Disconnect the battery negative terminal.

Place the car on a ramp.

- 7055B54 under-engine guard - r r

- 1048A10 air cleaner filtering element - replace

- 1056B14 throttle case - r + r

1. Remove the protective cap (1a) for the fuel manifold (1b) and use the tool (1c) for draining the fuel pressure.

Collect the fuel in a suitable container.

Removing

Place the car on the ramp.

Disconnect the battery negative terminal.

- 1048A32 sleeve from air cleaner to intake manifold - r + r

- 7055B54 under-engine guard - r r

- 1084A16 oil dip stick pipe - r r

- 1084A22 engine oil filler - r r

- 1072B50 sleeves connecting air capacity box to inlet manifold is - r+r

- 1072B14 inlet manifold - r+r and replace seal with air conveyor/box removed

Removing

- 7055B54 under-engine guard - r r

- 4450B04 right front wheel r r

- 1092G10 single engine belt r r

- 1032D12 timing system protective cover(s) - r + r

- 1032B10 toothed timing belt - r + r for timing adjustment or replacement

- 1060A35 injection pump toothed drive pulley - r+r with timing belt removed

- 1060A10 injection pump - r + r

1. Disconnect the electrical connections for the heater plugs.

2. Place the supply cables for the heater plugs at the side.

1. Disconnect the rapid attachment for the fuel supply pipe.

2. Disconnect the electrical connectors for the injectors.

3. Undo the bolts (3a) and remove the manifold pipe (3b).

Refitting

- 1072B14 inlet manifold - r+r and replace seal with air conveyor/box removed

- 1072B50 sleeves connecting air capacity box to inlet manifold is - r+r

- 1084A22 engine oil filler - r r

- 1084A16 oil dip stick pipe - r r

- 7055B54 under-engine guard - r r

- 1048A32 sleeve from air cleaner to intake manifold - r + r

Connect the battery negative terminal.

Remove the car from the ramps.

Position a hydraulic jack beneath the engine to support it.

1. Undo the three nuts securing the support to the bodyshell.

2. Undo the two nuts securing the mount to the engine.

3. Remove the engine mount, timing side.

1. Disconnect the electrical connection for the engine rpm sensor.

1. Unscrew the retaining bolts.

2. Remove the injection pump mount.

1. Undo retaining clip (1a) and disconnect injector wiring duct (1b) from slots (1c) on the cam cover.

1. Undo the retaining nuts.

2. Remove the intake manifold from the cylinder head.

1. Disconnect the electrical connection from the engine coolant temperature sensor.

Fit a suitable container for coolant recovery.

2. Undo the bolts (2a) fixing the plastic filler (2b), then move it away from the fastening on the intake manifold, complete with coolant hose (2c).

Refitting

Fit the intake manifold to the cylinder head.

Tighten the nuts securing the manifold to the cylinder head to the recommended torque.

Fit the injection pump support into its housing and tighten the crankcase securing bolts

Fit the timing side engine mount by screwing in the nuts securing it to the body and engine without tightening.

Remove the hydraulic lift positioned under the engine.

Position the wiring for the spark plugs and connect the connections to the actual plugs.

- 1060A10 injection pump - r + r

- 1060A35 injection pump toothed drive pulley - r+r with timing belt removed

- 1032B10 toothed timing belt - r + r for timing adjustment or replacement

- 1032D12 timing system protective cover(s) - r + r

- 1092G10 single engine belt r r

- 4450B04 right front wheel r r

- 7055B54 under-engine guard - r r

1. Disconnect the electrical connection from the intake air temperature/pressure sensor.

2. Disconnect the electrical connection for the anti-evaporation solenoid valve.

3. Disconnect the brake servo vacuum pipe (3a) and the anti-evaporatino system pipe (3b) from the manifold.

Remove the wiring for the injectors from the clips behind the intake manifold.

4. Disconnect the oil vapour recovery pipe, manifold side.

5. Undo the fixing nuts (5a) and remove the intake manifold (5b).

Refitting

Fit the intake manifold and tighten the cylinder head bolts to torque.

Connect the oil vapour recovery pipe to the tappet cover.

Secure the electrical wiring to the retaining bands located behind the intake manifold.

Connect the anti-evaporation pipe and secure it using the retaining band.

Connect the electrical connection for the intake air temperature/pressure sensor.

Connect the electrical connection for the anti-evaporation solenoid valve.

Connect the brake servo vacuum pipe and the anti-evaporation system pipe to the manifold.

Fit the plastic filler, complete with coolant hose.

Secure the filler to the intake manifold and tighten the fixing bolts.

Connect the electrical connection to the engine coolant temperature sensor.

Connect the electrical connection for the intake air temperature/pressure sensor.

Secure the injector wiring duct to the slots on the cam cover.

Connect the electrical connection for the engine rpm sensor.

Fit the manifold pipe and secure it using the bolts.

Connect the electrical connectors for the injectors.

Connect the rapid attachment for the fuel supply pipe.

- 1056B14 throttle case - r + r

- 1068A10 accelerator pedal control - check, adjust if necessary and lubricate

- 1048A10 air cleaner filtering element - replace

- 0010T21 coolant check density and top up if necessary

- 7055B54 under-engine guard - r r

Connect the battery negative terminal.

Remove the vehicle from the ramp.