Withdrawal
1. Relieve pressure in the fuel supply system (see chapter 4, section 2).
2. Disconnect the wire from the negative battery terminal.
3. Drain the coolant (see chapter 1, section 29).
4. Disconnect the upper radiator hose from the thermostat housing. If you need to replace the intake manifold, remove the thermostat (see chapter 3, section 3).
5. Disconnect the electrical connectors for the coolant temperature sensor and the EGR temperature switch (EGR) (see chapter 6, sections 4 and 7).
6. If you are going to replace the intake manifold, remove the throttle body (see chapter 4, section 12); if you intend to reuse the intake manifold, there is no need to remove the throttle body.
7. If you are going to replace the intake manifold, remove the EGR valve (see chapter 6, section 7).
8. Remove valve covers (see section 4).
9. Turn away bolts of fastening of an inlet collector (see illustration) and remove the manifold. Do not insert a lever between the manifold and the heads as this may damage the soft aluminum sealing surfaces at the gasket. If you are installing a new manifold, transfer all parts and sensors to it.
5.9. The intake manifold is secured with nine bolts and two nuts (shown by arrows); the numerical sequence indicated in the illustration is valid only for tightening the bolts (nuts) intake manifold during assembly - loosen them in reverse order
10. Cut the old intake manifold gaskets as shown in the illustration; take them off.
5.10. To remove the old intake manifold gaskets (or install new), cut the old gaskets in places (shown by arrows) behind the bars, where they pass in the form of narrow strips behind the bars
Installation
Note. The mating surfaces of the cylinder head, cylinder block and manifold must be perfectly clean before installing the manifold.
11. Use a scraper to remove traces of seal and gasket material, then clean mating surfaces with lacquer thinner or acetone. If sealant or grease remains on the mating surfaces when the manifold is installed, oil may leak through these areas. Use a vacuum cleaner to remove pieces of gasket material that may have fallen into the intake ports or pushrod recesses.
12. Clean the threads in the holes with a tap of the appropriate size, then use a jet of compressed air to remove the chips from the holes.
Attention! When using compressed air to protect your eyes, wear safety goggles or a visor!
13. Apply a blot of 3/16" RTV sealant to the front and rear ridges of the cylinder block between the cylinder heads (5 mm) (see illustration).
5.13. Apply a drop of sealant to the edges between the cylinder heads (shown by arrows) or install seals on them
Note. A number of gasket kits have mechanical seals that can be used instead of sealant here.
14. Cut new gaskets for the intake manifold in the same places where the old ones were cut and install them.
15. Carefully lower the manifold into place and tighten the bolts by hand (nuts).
16. Tighten the bolts (nuts) in two steps, following the sequence shown in illustration 5.9, until all of them are tightened to the required torque specified in section "Tightening torques" of this chapter.
17. Install other parts in reverse order.
18. Change oil and oil filter, charge the cooling system (see chapter 1, sections 12 and 29). Start the engine and check the system for leaks.