Note: Please refer to the warning in Chapter 2. Use new gaskets when installing.
Removing
1. Disconnect the negative cable from the battery.
2. Remove the idle speed control and hoses, if necessary, refer to Chapter 22.
3. Release the retaining clip, then disconnect the cable and ball joint from the throttle lever. Pull the cable o-ring off the bracket on the intake manifold, and move the cable to the side.
4. Loosen the screws and disconnect the main air line from the throttle body.
5. Unscrew the union nut, disconnect the brake booster vacuum hose from the intake manifold (see illustration).
6. Disconnect the camshaft cover breather hose from the throttle body.
7. Disconnect the coolant hoses from the throttle body. Seal the open ends of the hoses to prevent further loss of coolant.
8. Disconnect the electrical wiring from the throttle position sensor.
9. Disconnect the vacuum pipe from the fuel pressure regulator.
10. Disconnect the wiring harness cover from the fuel injectors, move it to the side; be careful not to deform the wiring. Pull the shroud, pinch the harness connector retaining clips to release the harness shroud from the injectors.
11. Disconnect the fuel supply hoses from the fuel line. Seal the open ends of the hoses to prevent dirt from entering and further fuel leakage.
12. Turn off and remove the top nut and a bolt of fastening of the generator.
13. Make a final check that all relevant hoses, pipes and wires are disconnected.
14. Turn off fixing nuts, remove a collector from a head of the block of cylinders, remove a lining (see illustrations).
15. It is possible that when unscrewing the fixing nuts from the cylinder head, the racks can be unscrewed.
In this case, the struts must be screwed back into the head.
16. If required, following the appropriate Section, auxiliary components can be removed from the manifold.
Installation
17. Install in reverse order, pay attention to the following.
18. Where applicable, install accessories to the manifold, referring to the appropriate Section Chapters 4A or 4B.
19. If the generator mounting bracket was unscrewed from the manifold, first install it, and then the manifold.
20. Install the manifold using a new gasket, tighten the fixing nuts with the tightening torque specified specifications.
21. Make sure all hoses, pipes and wires are properly connected.
22. Finally, check the coolant level and top up if necessary (Section 3).
23. Check and, if necessary, adjust the throttle cable play as described in Sections 4A or 4B, depending on the model.
24. If the connections of the fuel system components are broken, check and adjust the idle mixture as described in Sections 4A or 4B, depending on the model.
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