Table of contents: Removal ↓ Installation ↓
Note: Before starting the procedure, please refer to the warning in paragraph 1.
Removal
1. Disconnect the ground cable from the battery as described in chapter 5A.
2. If equipped, remove the top engine cover.
3. Drain the cooling system as described in chapter 1A. On non-turbo models, use suitable clamps to clamp the system hoses leading to the throttle body.
4. If the coolant is draining, loosen the clamps and disconnect the two hoses from the expansion tank located on the left side of the engine.
5. Loosen the mounting screws and lift the expansion tank. Disconnect the wiring from the emergency fluid level sensor. Remove the tank from the car. If you are not draining the fluid, move the tank to the rear of the engine compartment away from the intake manifold.
6. Disconnect the accelerator cable from the throttle body and mounting bracket as described in paragraph 3.
7. On models with cruise control, disconnect the actuator rod from the throttle body.
8. Disconnect the vacuum hose from the canister purge valve on the intake manifold.
9. Disconnect the brake booster vacuum hose from the intake manifold
10. On non-turbocharged models, remove the intake air duct between the throttle body and air cleaner and also disconnect the PCV hose if necessary. Remove the duct from under the hood.
11. On turbocharged models, disconnect the intake air duct from the throttle body to the left of the engine
12. Disconnect the wiring and fuel pressure regulator hose from the throttle body. Loosen the clamps and disconnect the coolant hoses from the throttle body. Remove the throttle body from the intake manifold as described in paragraphs 4 or 5.
13. On ADR and AFY engines built before 07/1997, disconnect the wiring from the air temperature sensor.
14. On ADR and AFY engines built after 08/1997, disconnect the wiring from the air temperature sensor and the intake manifold changeover valve.
15. Unscrew the fuel rail mounting bolts and remove it together with the injectors from the intake manifold, placing it in the rear of the engine compartment on a clean cloth. On ADR. AFY, AHL, AEB and AJL engines, also disconnect the wiring from the Hall sensor at the front of the engine.
16. On ADP engines, remove the upper coolant pipe from the top of the intake manifold, loosen the clamps and disconnect the hoses from both sides of the pipe. Remove the pipe from the engine.
17. On AEB and AJL engines, disconnect the hoses from the upper coolant pipe. Remove the pipe from the intake manifold and the flange at the rear of the cylinder head.
18. Unscrew the bolt and nuts securing the support brackets to the intake manifold. Unscrew the nuts from the rubber supports (fig. 10.18, a, b).
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19. Remove the dipstick. On ADR engines, note the position of the coolant hose between the center channels of the intake manifold (fig. 10.19, a, b).
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20. Unscrew the nuts and bolts securing the intake manifold to the cylinder head. Remove the manifold and gasket (fig. 10.20, a-c).
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Installation
21. Installation is the reverse procedure of removal, taking into account the following.
- a) Ensure that the mating surfaces are clean and dry and install a new gasket.
- b) Install the manifold, tightening its mounting nuts evenly and gradually to the prescribed torque.
- c) Check and, if necessary, adjust the accelerator cable - see paragraph 3.
- d) Add fluid to the cooling system as described in chapter 1A.
- d) Connect the battery - see chapter 5A.
[The full version is posted on the resource Audimanual.ru]