Inlet and exhaust manifold gasket (page 4 of 4)

Refit

1. Clean mating faces of inlet manifold, exhaust manifold and cylinder head.
2. Fit new exhaust manifold gasket to cylinder head.
3. Fit exhaust manifold to cylinder head.
4. Locate breather pipe on exhaust manifold stud.
5. Align breather pipe to cylinder head, fit bolt and tighten to 9 Nm.
6. Connect HO2S multiplug to harness.
7. Secure HO2S lead to harness with cable tie.
8. Clean inlet manifold locating rings.
9. Fit 2 inlet manifold locating rings to cylinder head.
10. Fit inlet manifold to cylinder head.

11. Fit nuts and washers securing manifolds to cylinder head. Working in the sequence illustrated, tighten nuts to 22 Nm.
12. Fit front pipe to manifold gasket. See this section.
13. Connect evaporative emission canister purge hose to inlet manifold and secure with clip.
14. Connect breather hose to inlet manifold.
15. Position air cleaner mounting bracket to fuel rail and inlet manifold.
16. Align fuel return pipe ’P’ clip to inlet manifold.
17. Fit bolts securing mounting bracket to inlet manifold and fuel rail. Tighten bolts to 9 Nm.
18. Secure harness clips to mounting bracket.
19. Remove plugs from fuel pipes and fuel hose quick fit connectors.
20. Clean ends of fuel pipes.
21. Connect fuel return hose connector to fuel return pipe.
22. Connect fuel feed hose connector to fuel feed pipe.

CAUTION: Ensure quick fit connectors are correctly engaged on fuel pipes.

23. Remove cloth position to absorb fuel spillage.
24. Connect multiplug to IAT sensor.
25. Connect multiplug to IACV.
26. Connect multiplugs to fuel injectors.
27. Connect multiplug to TP sensor.
28. Connect multiplug to MAP sensor.
29. Connect brake servo vacuum pipe to inlet manifold.
30. Connect throttle cable to throttle cam and locate adjusting nut to abutment bracket.
31. Connect battery earth lead.
32. Adjust throttle cable. See ENGINE MANAGEMENT SYSTEM - MEMS, Adjustments.