Inlet manifold gasket - ’k’ series (page 4 of 4)

Refit

1. Ensure mating surfaces are clean and that metal inserts are fitted in inlet manifold stud and bolt holes.
2. Fit new gasket to inlet manifold.

CAUTION: Gasket must be fitted dry.

3. Fit inlet manifold, fit bolts and nuts and tighten to 17 Nm in the sequence shown.
4. Connect coolant hose to inlet manifold and tighten clip.
5. Remove plugs from fuel hoses.
6. Lubricate a new ’O’ ring with silicon grease and fit to fuel feed pipe.
7. Position fuel feed pipe to fuel rail, fit bolts and tighten to 10 Nm.
8. Connect multiplug to injector harness and secure multiplug to bracket.
9. Connect multiplug to air temperature sensor.
10. Connect fuel return hose to fuel rail, secure with clip.
11. Fit fuel return hose to clips on manifold.
12. Connect ECM vacuum pipe and brake servo vacuum hoses to inlet manifold.
13. Connect breather pipe to inlet manifold.
14. Secure distributor h.t. cable in clip.
15. Connect multiplug to stepper motor.
16. Clean inlet manifold and throttle body mating surfaces.
17. Lubricate a new ’O’ ring with silicon grease and fit to throttle body.
18. Position throttle body to inlet manifold, fit bolts and tighten to 4 Nm.
19. Secure throttle cable in clips on inlet manifold.
20. Connect multiplug to throttle position sensor.
21. Connect breather hose to throttle body and tighten clip.
22. Connect hose to stepper motor and secure clip.
23. Connect purge hose to inlet manifold and tighten clip.
24. Connect air hose to air cleaner and tighten clip.
25. Refill cooling system. See COOLING SYSTEM, Adjustments.
26. Connect battery earth lead.