Gasket - Inlet Manifold - Upper

GASKET- INLET MANIFOLD- UPPER
Service repair no - 30.15.24


Remove
1. Release 3 fixings and remove battery cover.
2. Disconnect battery earth lead.
3. Remove gas struts from bonnet.
4. With assistance support bonnet on hinge extension arms.




5. Loosen 2 clips securing air intake hose, release air intake hose and disconnect harness from clip on hose.
6. Release clip securing IAC hose to air intake hose and remove air intake hose.




7. Remove 2 bolts securing abutment bracket to plenum chamber and position aside.
8. Release throttle and cruise control cables from clips and throttle cams and position aside.




9. Disconnect EVAP pipe from plenum chamber and clip on upper manifold.
10. Disconnect multiplug from TP sensor.
11. Release clip securing breather hose to throttle body and release breather hose.
12. Release clip and disconnect IAC hose from plenum chamber.





13. Position a container below throttle body to collect coolant.
14. Release clips securing coolant hoses to throttle body and release hoses.




15. Release clip and disconnect engine breather hose from plenum chamber.
16. Remove bolt securing coolant rails.




17. Remove 2 cable ties securing engine harness to clip on upper manifold.




18. Release HT leads from clips on upper inlet manifold.
19. Disconnect multiplug from IAC valve.




20. Remove 2 bolts securing top of coils.
21. Loosen 2 bolts securing bottom of coils to block but do not remove bolts.




22. Remove 6 bolts securing upper manifold and remove upper manifold.
23. Collect upper manifold gasket.


Refit
24. Clean inlet manifold and upper manifold mating faces, dowels and dowel holes.
25. Using a new gasket, position upper manifold. Fit bolts, and working in a diagonal sequence, tighten to 22 Nm (16 ft. lbs.).
26. Fit 2 top bolts securing coils to manifold and tighten all coil fixing bolts to 8 Nm (6 ft. lbs.).
27. Connect IAC valve multiplug.
28. Secure HT leads to upper manifold clips.
29. Connect multiplug to TP sensor.
30. Position engine harness in manifold clip and secure with new cable ties.
31. Fit and tighten coolant rail bolt to 22 Nm (16 ft. lbs.).
32. Connect breather hose to plenum and secure with clip.
33. Connect IAC hose to plenum chamber and secure with clip.
34. Position coolant hoses to throttle body and secure hose clips.
35. Fit breather hose to throttle body and secure clip.
36. Connect multiplug to TP sensor.
37. Connect EVAP pipe to plenum chamber and clip on upper manifold.
38. Connect throttle and cruise control cables to clips and secure in throttle body cams.
39. Position abutment bracket to upper manifold, fit and tighten bolts.
40. Fit air intake hose, tighten 2 clips and connect harness to clip on hose.
41. Connect IAC hose to air intake hose and secure with clip.
42. Top-up cooling system.
43. Lower bonnet and connect gas struts.
44. Connect battery earth lead.
45. Fit battery cover and secure fixings.