Table of contents: 3.0L 1st generation and 3.0L SCR… ↓ Engines 3.0 l 2nd generation ↓ 4.2L engines ↓
3.0L 1st generation and 3.0L SCR engines
1. The installation details of the intake manifold are shown in the illustrations using the left side as an example.
4.1a. BUG/BUN engine intake manifold installation details:
1 - EGR connecting pipe;
2 - Inlet connecting pipe;
3, 21, 24, 26 - Gasket, subject to replacement;
4-6, 8, 12, 18, 19, 25 - Bolt, 9 Nm;
7 - Upper section of the intake manifold;
9, 17 - Gasket;
10 - Engine upper cover retaining pin, 9 Nm;
11 - Activator "V157" (on the right side - "V275") of the intake manifold flap;
13 - Retainer, do not disassemble;
14 - Traction, don't disassemble;
15 - Connection;
16 - Lower section of the intake manifold;
20 - Threaded plug, 25 Nm;
22 - Air hose;
23 - Throttle body module "J338".
4.1b. Installation details of the intake manifold for CASA/CASB, CCMA and CATA engines:
1 - Reinforced clamp, 5.5 Nm;
2 - Throttle body module "J338", 9 Nm;
3 - O-ring, must be replaced;
4, 5, 11, 13 - Bolt, 9 Nm;
6, 9 - Gasket, subject to replacement;
7 - EGR connecting pipe;
8 - Upper section of the intake manifold;
10 - Threaded plug, 10 Nm;
12 - Engine top cover retaining pin, 5 Nm;
14, 21 - Gasket;
15 - Activator "V157" (on the right side - "V275") of the intake manifold flap;
16 - Bolt, 10 Nm;
17 - Retainer;
18 - Thrust;
19 - Connection;
20 - Lower section of the intake manifold;
22 - Air hose.
Before starting work, remove the upper engine cover (see Section 19 of Chapter 1).
BUG/BUN engines
2. If the lower section of the intake manifold needs to be removed, drain the coolant (see Chapter 3), give away the union nuts (1-4 in illustration 13.35 Chapter 2) and remove the high pressure pipes.
3. Release the fasteners (1 in the illustration), tilt the fuel injection pump belt cover forward and release the locking tabs on the underside of the cover.
4.3. Timing belt cover clamps.
4. Disconnect the air inlet hose (5 in the illustration) from the throttle module and disconnect its connector (6).
4.4. Connections and fastening of the connecting inlet pipe.
Remove bolts (3 and 4) and separate the inlet connecting pipe from the throttle module.
5. Remove the bolts (see illustration) and carefully remove the upper section of the intake manifold.
4.5. Bolts for fastening the upper section of the intake manifold.
Once the top section has been removed, the bottom section of the intake manifold can be removed as described below: the left section in paragraphs 6-9, and the bottom section in paragraphs 10-13.
6. Remove the mechanical EGR valve (see Part B).
7. Turn out the retaining pin (2 in the illustration) upper casing, unhook the EGR cooler switching valve "N345" (1) from the bracket and disconnect the connector of this valve.
4.7. Retaining pin (2) of the upper casing and valve N345 (1).
8. Unscrew the hollow bolt of the cooling system bleed pipe (see illustration).
4.8. Hollow bolt of the cooling system bleed pipe.
9. Disconnect the connector (1 in the illustration) activator No. 2 "V275" of the intake manifold flap.
4.9. Fastening the left lower section of the intake manifold.
Unscrew the bolts (arrows), push the cooling system bleed tube to the side and remove the lower section of the intake manifold together with its valve. Plug the intake ports to prevent dirt from getting in.
10. Remove the air hose (see illustration).
4.10. Air hose clamps.
11. Remove the connector of the exhaust gas temperature sensor No. 1 "G235" from the bracket (see illustration).
4.11. Sensor connector G235.
12. Disconnect the connector (3 in the illustration) activator "V157" of the intake manifold flap, unscrew the bolt (2) and disconnect the connectors of the glow plugs of the right row of cylinders.
4.12. Connections on the right lower section of the intake manifold.
13. Remove the bolts (see illustration 21.34 Chapter 2) and remove the lower section of the intake manifold. Plug the intake ports to prevent dirt from getting in.
14. Installation is carried out in reverse order. Use new sealing parts. Before installing the left lower section, screw in the hollow coolant pipe bolt with a new seal 2-3 turns.
CASA/CASB, CATA and CCMA engines
15. Remove the oil dipstick. Loosen the clamp (3 in the illustration) and remove the air hose.
4.15. Clamp (3) and connector (4).
Disconnect the connector (4).
16. Unscrew the fastener bolts (arrows in the illustration), loosen the union nuts (1 and 4) and separate the fuel pressure pipe.
4.16. Fixing bolts (arrows) and union nuts (1 and 4).
17. Turn out the retaining pins (1 and 2 in the illustration) upper engine casing and bolts (arrows) of the upper section of the intake manifold.
4.17. Retaining pins (1 and 2) of the upper casing and bolts (arrows) of the upper section of the intake manifold.
Remove the upper section of the intake manifold. Once the top section has been removed, the bottom section of the intake manifold can be removed as described below: the left section in paragraphs 18-21, and the bottom section in paragraphs 22-26.
18. Carefully press the rod (2 in illustration 21.27 Chapter 2) from the "V275" activator in the direction of the arrow, disconnect the connector (1), unscrew the bolts (3) and remove the "V275" activator (4). Disconnect the connectors of the glow plugs of cylinders No. 4-6.
19. Remove the "N345" valve from the bracket (1 in the illustration) switching the EGR radiator and unscrew the bolt (4).
4.19. Valve "N345" (1) and bolt (4).
20. Remove the bolts (see illustration).
4.20. Fastening the lower left section of the intake manifold.
21. Loosen the clamp (arrow in illustration 21.29 Chapter 2) and separate the EGR pipe (1). Carefully remove the lower section of the intake manifold.
22. Remove the bolts, (arrows in illustration 11.34 Chapter 2) and remove the protective plate of the pressure fuel pipes. Loosen the union nuts (1 and 4) and remove the high pressure fuel line.
23. Disconnect the connector (2 in illustration 5.5 Chapter 3) of the "V400" EGR radiator pump and unscrew the bolts (1).
24. Remove the connectors from the bracket (1 and 2 in Illustration 21.35 of Chapter 2).
25. Disconnect the connector (3 in illustration 4.12) activator "V157" of the intake manifold flap, separate the rod (1) from it and unscrew the bolts (4). Disconnect the glow plug connectors for the right bank of cylinders. Set the wiring aside.
26. Remove the bolts (arrows in illustration 21.34 Chapter 2) push the coolant pipe to the side and remove the lower section of the intake manifold. Plug the intake ports to prevent dirt from getting in.
27. Installation is carried out in reverse order. Use new sealing parts.
Engines 3.0 l 2nd generation
28. The details of the intake manifold installation are shown in the illustration.
4.28. Installation details of the intake manifold of the 3.0 L 2nd generation engines:
1 - Air tube bracket;
2, 3, 5, 6, 10, 18, 21, 28 - Bolt, 9 Nm;
4, 8, 22 - Gasket;
7 - Activator "V157" of the intake manifold;
9 - Inlet manifold;
11, 19 - Support pin for upper engine casing, 5 Nm;
12 - Electrical wiring connector bracket;
13, 15 - Bolt, 4 Nm;
14 - Electrical wiring guide;
16, 26, 30 - Gaskets, subject to replacement;
17 - Bracket for EGR cooler switching valve "N345";
20 - Air tube;
23, 31 - Screw clamp;
24 - Air hose;
25 - Throttle module "J338";
27, 29 - EGR pipe.
29. Before starting work, remove the upper engine cover (see Section 19 of Chapter 1). Removal of the throttle module is described in paragraph 30, and removal of the intake manifold is described in paragraphs 31-43.
30. To remove the throttle body module "J338", loosen the clamp (3 in the illustration), disconnect the air hose, disconnect the connector (1) and unscrew the bolts (2).
4.30. Connections and fastening of the throttle module "J338".
Installation is carried out in reverse order. Use a new gasket.
31. Using a suitable lever, remove from the guide (1 in the illustration) electrical wiring and hoses.
4.31. Removing the guide (1).
Pull the coolant hose back (arrow), unscrew the bolts (2 and 3) and remove the guide (1).
32. Remove the bolts (1 and 2 in the illustration) and remove the holder (3).
4.32. Removing the fuel pressure pipe.
Unscrew the union nuts (arrows) and remove the upper fuel pressure pipe.
33. Separate the electrical wiring connectors (1 and 2 in the illustration) and remove the non-return valve (3) from the bracket.
4.33. Non-return valve (3).
34. Unscrew the bolt (2 in the illustration) fuel pressure pipe holder.
4.34. Bolt (2) of fuel pipe holder.
35. Disconnect the connector (2 in the illustration) coolant valve "N489" (1) for cylinder head.
4.35. Connector (2) of valve "N489" (1).
Remove the bolts (arrows) and set the bracket with the "N489" valve aside.
36. Disconnect the ECT sensor connector (see illustration).
4.36. ECT sensor connector.
37. Disconnect the connectors (1 and 2 in Illustration 28.9 of Chapter 2) and move the electrical wiring to the left side.
38. Unscrew the bolt (3 in illustration 28.12 Chapter 2) from the central bracket of the intake manifold and the bolt (2) of the oil dipstick guide tube.
39. Loosen the clamp (2 in illustration 31.24 Chapter 2) EGR pipes.
40. Remove the bolts (2 in illustration 31.4 Chapter 2) from the left air tube bracket.
41. Disconnect the connector (1 in illustration 4.30) module "J338" throttle valve, loosen the clamp (3) and disconnect the air hose.
42. Disconnect the glow plug connectors and remove the fuel pressure sensor "G247" (see illustration).
4.42. Fuel pressure sensor "G247".
43. Remove the bolts (1-4 and arrows in the illustration) and remove the intake manifold.
4.43. Intake manifold mounting bolts.
44. Installation is carried out in reverse order. Use new sealing parts. Tighten everything first (1-4 and arrows in illustration 4.43) tighten the intake manifold mounting bolts by hand, then tighten the bolts (1-4) to 9 Nm, and then tighten the bolts (arrows) to 9 Nm.
4.2L engines
45. The details of the installation of the intake manifold are shown in the illustration using the left side as an example.
4.45. Installation details of the intake manifold for 4.2L engines:
1 - Air inlet connection;
2, 7, 8, 14, 16, 17, 21, 23 - Bolt, 9 Nm;
3, 5, 25 - O-ring, subject to replacement;
4 - Throttle module;
6, 10, 19, 22 - Gasket, subject to replacement;
9 - EGR cooler connection;
11 - Engine top cover retaining pin, 5 Nm;
12 - Upper section of the intake manifold;
13 - Bracket for switching valve and electrical wiring connectors;
15 - Threaded plug, 8 Nm;
18 - Switch valve bracket;
20 - Lower section of the intake manifold;
24 - Boost pressure sensor "G31" with IAT sensor "G42".
46. Remove the upper engine cover (see section 19 of Chapter 1).
47. On the BTR engine, unscrew the bolt (2 in the illustration) high pressure tube holders.
4.47. Bolt (2) of the pressure pipe holder.
48. On the BTR engine, loosen the union nuts (3 and 4 in the illustration), unscrew the bolt (5) of the holder and remove the fuel pressure pipe.
4.48. Connection on the top side of the intake manifold (BTR).
Separate the electrical wiring connector (6) from the bracket, disconnect the connector and move the wiring to the side. Disconnect the connector fl in the illustration), remove the EGR cooler switching valve "N345" (2) from the bracket and pull out the vacuum hose.
49. On CCFA/CCFC engines, loosen the union nuts (arrows in the illustration), unscrew the bolt (3) on the holder and remove the pressure pipe.
4.49. Connection on the upper side of the inlet manifold (CCFA/CCFC).
Remove the connectors (4 and 5) from the bracket and disconnect them. Disconnect the connector (1) and move the wiring harness to the left. Unscrew the bolts (2), remove the EGR cooler switching valve "N345" and remove the vacuum hose.
50. On the CCFC engine, remove the nuts (arrows in illustration 35.18 Chapter 2) and move the wiring harness from the engine to the left.
51. Disconnect the connector (1 in illustration 3.59 Chapter 3) module No. 2 "J544" throttle valve and connector (6) module "J338" throttle valve. Loosen the clamps (2 and 5) and disconnect the air hoses.
52. On the CCFC engine, remove the bolts (1 in the illustration) and press the coolant valve "N489" (arrow) for the cylinder head together with the bracket to the side.
4.52. Valve "N489" (arrow) and its bracket bolts (1) on the CCFC engine.
53. Remove the upper engine cover retaining pins (1 and 6 in the illustration).
4.53. Fastening the upper section of the intake manifold.
Remove the bolts (7) on the EGR radiator connection, remove the bolts (2-5) and remove the upper section of the intake manifold. If necessary, after removing the upper section of the intake manifold, its lower section can be removed as described below: right side - in paragraphs 54-58, left side - in paragraphs 59-61.
54. On the BTR engine, unscrew the bolt (2 in illustration 4.47) fuel pressure pipe holder, loosen the connections (1 and 3) and separate the injector pipe.
55. On the BTR engine, unscrew the bolts (3 and 5 in Illustration 42.30 Chapter 2) and carefully press the "V338" EGR activator together with the connection to the side so that the bolts on the lower section of the intake manifold are accessible.
56. On CCFA/CCFC engines, drain the coolant (see Chapter 3), unscrew the bolts (2 in the illustration) coolant pipes, loosen the clamps (arrows) and move the pipe to the side.
4.56. Removing the coolant pipe.
Unscrew the bolt (1) on the holder.
57. On CCFA/CCFC engines, remove the bolts (1 in the illustration), carefully push the "V338" EGR actuator together with the connection to the side so that the bolts on the lower section of the intake manifold are accessible.
4.57. EGR actuator fastening.
Also move the fuel hose to the side.
58. Disconnect the connector (1 in the illustration) activator "V157" of the intake manifold flap, unscrew the bolts (arrows) and remove the lower section of the intake manifold with the activator "V157" of its flap.
4.58. Fastening the right lower section of the intake manifold.
Plug the intake ports to prevent dirt from getting in.
59. Disconnect the glow plug connectors of cylinders No. 5-8.
60. On the BTR engine, remove the non-return valve from the holder, disconnect the fuel injection pump connectors (1 in illustration 42.13 Chapter 2) and activator No. 2 "V275" (2) of the intake manifold flap. Unscrew the bolts (arrows) and remove the lower section of the intake manifold with activator No. 2 "V275" of its valve. Plug the intake ports to prevent dirt from getting in.
61. On CCFA/CCFC engines, remove the non-return valve from the holder (2 in the illustration) and disconnect the connector (1) of the activator No. 2 "V275" of the intake manifold flap.
4.61. Fastening of the right lower section of the intake manifold (CCFA/CCFC).
Unscrew the bolts (arrows) and remove the lower section of the intake manifold with activator No. 2 "V275" of its valve. Plug the intake ports to prevent dirt from getting in.
62. Installation is carried out in reverse order. Use new sealing parts.
(Material republished from the website «audimanual»)