Removal and installation of an inlet collector

Upper intake manifold

Withdrawal

1. Disconnect the negative battery cable (chapter 5, paragraph 1).

2. Turn out bolts of fastening of a plastic cover to the top part of a forward head of the block. One of the bolts is attached to the cooling system hose. Remove the cover (see fig. 6.2, a, b).



3. Disconnect the crankcase ventilation hoses from the intake duct and valve of the RVG system (see fig. 6.3, a-c).







4. Pull the vacuum hose off the top section of the intake manifold (see fig. 6.4).




5. Loosen the two clamps and disconnect the intake duct from the throttle body and air flow meter. Remove the duct (see fig. 6.5, a, b).



6. Pull the brake booster vacuum hose off the top section of the intake manifold (see fig. 6.6).



7. Use a screwdriver to release the retainer, then disconnect the throttle and cruise control cables from the bracket (see fig. 6.7).




8. Remove the bolts and remove the throttle cable bracket (see fig. 6.8).



9. Disconnect wiring from idle air valve and throttle position sensor (see fig. 6.9, a, b).



10. Disconnect the vacuum hose from the RVG system valve. Then turn out bolts of the valve and remove a lining. If necessary, pull the valve out of the pipe (see fig. 6.10, a-c).






11. Disconnect the positive crankcase ventilation hose from the intake manifold (see fig. 6.11).



12. Disconnect the wiring and vacuum hoses from the vacuum regulator of the RVG system (see fig. 6.12, a, b).



13. In the reverse order shown in fig. 5.20, turn out bolts of the top section of an inlet collector, and then remove it. Remove the gaskets from the bottom section of the intake manifold. Remove the rubber insulators from the mounting bolts and inspect them. If they are not suitable, replace them (see fig. 6.13, a-g).

Installation

14. Clean the mating surfaces of the upper and lower sections of the intake manifold.

15. Install new gaskets on the lower section of the manifold. Install the top section of the manifold. Insert bolts (see fig. 6.15) and tighten them to the required torque in the sequence shown in fig. 5.20.



16. Connect wiring and vacuum hose to RVG vacuum regulator.

17. Connect the positive crankcase ventilation hose to the intake manifold.

18. Install the RVG system valve with a new gasket and tighten the bolts. Install the vacuum hose.

19. Attach the wiring to the throttle position sensor and the intake manifold air temperature control valve.

20. Install throttle cable bracket and tighten bolts.

21. Install throttle and cruise control cables to bracket and install retainer.

22. Attach two brake booster vacuum hoses to the top section of the intake manifold.

23. Install the intake duct and tighten the bolts.

24. Connect the vacuum hose.

25. Connect the crankcase ventilation hoses to both sides of the intake duct.

26. Install the plastic cover on top of the front block head. Fix a hose of system of cooling.

27. Connect the negative battery cable (chapter 5, par 1).

Note: To restore the settings of the engine management system due to battery disconnection, a mileage of about 16 km is required. In this case, the engine may not work normally.

Lower intake manifold

Withdrawal

28. Eliminate the residual pressure of the fuel system (chapter 4A).

29. Disconnect the negative battery cable (chapter 5A, par 1).

30. Remove the upper intake manifold section as above.

31. Disconnect the fuel inlet and outlet pipes. Use a special tool to disassemble special connections. Or make a fixture by twisting a piece of thin plastic tape 15 mm wide into a skein. Insert this coil into the open end of the connection so that the inner spring is lifted over the stopper. Then disassemble the piping connections.

32. Disconnect the wiring from the coolant temperature sensor (above the starter) and from the back pressure sensor of the RVG system on the thruster at the rear left. Then disconnect the wiring from the injectors.

33. Disconnect the vacuum hose from the fuel pressure regulator.

34. Disconnect the rod or cable of the intake system drive with a resonator from the stud and bracket on the cover of the front head of the block and disconnect the vacuum hose from the solenoid of this drive.

35. Turn out bolts of the bottom section of an inlet collector in sequence, return shown on fig. 6.40.

36. Remove the lower section of the intake manifold from the block heads and remove the gaskets (see fig. 6.36, a-c.).

Installation

37. Clean the mating surfaces of the manifold and block heads so as not to damage them.

38. Install new gaskets on the block heads.

39. Carefully place the manifold section on the gaskets without moving them.

40. Insert the bolts and tighten them to the required torque 8 in the sequence shown in fig. 6.40.



41. Attach the vacuum hose or intake drive rod with resonator.

42. Connect the vacuum hose to the fuel pressure regulator.

43. Connect the wiring to the injectors, the RVG system back pressure sensor, and the coolant temperature sensor.

44. Attach fuel lines.

45. Connect the negative battery cable (chapter 5, par 1). Note: To restore the settings of the engine management system due to battery disconnection, a mileage of about 16 km is required. In this case, the engine may not work normally.