Gasket - Inlet Manifold - Lower

GASKET- INLET MANIFOLD - LOWER
Service repair no - 30.15.08

Remove
1. Remove RH and LH rocker cover gaskets.




2. Disconnect multiplugs from coils.
3. Remove 2 bolts securing coils and remove coils.




4. Release leads from fuel rails and disconnect LH and RH injector multiplugs.
5. Position absorbent cloth to catch any fuel spillage and disconnect fuel pipe.

CAUTION: Plug the connections.

6. Remove auxiliary drive belt.




7. Remove 2 nuts securing leads to alternator and release leads.




8. Release clip securing top hose to outlet pipe and release hose.
9. Remove 2 bolts securing alternator and remove alternator.




10. Disconnect multiplug from compressor.
11. Remove 4 bolts securing compressor to mounting bracket and position compressor aside.




12. Remove 2 bolts securing PAS pump to mounting bracket and position aside.




13. Remove bolt securing jockey pulley to mounting bracket and remove pulley.
14. Remove 4 bolts and one nut securing mounting bracket and remove mounting bracket.




15. Remove 4 bolts securing top hose outlet pipe and remove outlet pipe.
16. Remove and discard O-ring.
17. Disconnect ECT sensor multiplug.




18. Using the sequence shown, remove 12 bolts securing inlet manifold.
19. Remove inlet manifold assembly.




20. Remove 2 bolts securing manifold gasket clamps and collect gasket clamps.
21. Remove inlet manifold gasket.
22. Remove gasket seals.


Refit
23. Clean RTV from head and block notches.
24. Clean mating faces of block, head and manifold.
25. Apply RTV silicone sealant in the four 'v' shaped notches between the ends of the cylinder head and the cylinder block joint.
26. Fit new gasket seals, ensure ends engage correctly in notches.
27. Fit new manifold gasket.
28. Position gasket clamps, fit bolts but do not tighten at this stage.
29. Position inlet manifold assembly.

NOTE: When fitting inlet manifold bolts, tighten in reverse of removal sequence.




30. Fit manifold bolts and in the sequence shown tighten bolts initially to 10 Nm (8 ft. lbs.), then tighten to 51 Nm (38 ft. lbs.).
31. Tighten gasket clamp bolts to 18 Nm (14 ft. lbs.).
32. Connect fuel pipe.
33. Connect multiplug to ECT sensor.
34. Clean top hose outlet pipe mating faces.
35. Lubricate and fit new O-ring to outlet pipe.
36. Position outlet pipe, fit and tighten bolts to 22 Nm (16 ft. lbs.).
37. Position mounting bracket, fit and tighten, bolts to 40 Nm (30 ft. lbs.), and nut to 10 Nm (7 ft. lbs.).
38. Fit jockey pulley and tighten bolt to 50 Nm (37 ft. lbs.).
39. Clean PAS pump dowels and dowel holes.
40. Position PAS pump to mounting bracket, locate on dowels and fit and tighten bolts to 40 Nm (30 ft. lbs.).
41. Clean compressor dowels and dowel holes.
42. Position compressor, locate on dowels and fit and tighten bolts to 25 Nm (18 ft. lbs.).
43. Connect multiplug to compressor.
44. Position alternator, fit and tighten bolts to 45 Nm (34 ft. lbs.).
45. Position top hose and secure clip.
46. Connect alternator cables, fit nuts and tighten B+ nut to 18 Nm (13 ft. lbs.) max and D+ nut to 5 Nm (3.5 ft. lbs.) max. B+ and D+ are marked on the rear of the alternator, adjacent on each cable connector. Fit leads to alternator and tighten nuts.
47. Fit auxiliary drive belt.
48. Connect injector multiplugs and secure leads to fuel rail.
49. Position coils and fit bolts but do not tighten at this stage.
50. Connect multiplugs to coils.
51. Fit rocker cover gaskets.