Intake Manifold: Service and Repair

30.15.37 Seals - inlet manifold chamber - from 03MY

Remove

1. Disconnect battery earth lead.
2. Remove vacuum enhancer. Service and Repair
3. Position absorbent cloth around fuel feed pipe connection to collect spillage.

WARNING: The spilling of fuel is unavoidable during this operation. Ensure that all necessary precautions are taken to prevent fire and explosion.






4. Pull back rubber sleeve on fuel pipe connector, release connector and disconnect fuel pipe from fuel rail pipe.

CAUTION: Always fit plugs to open connections to prevent contamination.

5. Release and disconnect EVAP hose from purge control valve.

CAUTION: Always fit plugs to open connections to prevent contamination.

6. Disconnect multiplug from purge control valve.





7. Non NAS models: Disconnect small vacuum pipe from purge control valve.
8. Non NAS models: Depress locking collar and release vacuum pipe from IACV housing.

CAUTION: Always fit plugs to open connections to prevent contamination.

9. Non NAS models: Disconnect multiplug from IACV.
10. Non NAS models: Disconnect multiplug from TP sensor.





11. Non NAS models: Depress locking collars and release vacuum/breather pipe from purge control valve and LH camshaft cover. Release clip securing hose to 'T' piece and remove pipe.

CAUTION: Always fit plugs to open connections to prevent contamination.

12. Non NAS models: Depress locking collars and release vacuum/breather pipes from throttle body, LH and RH camshaft cover and remove pipe.

CAUTION: Always fit plugs to open connections to prevent contamination.






13. Non NAS models: Release throttle cable from clips on harness brackets.
14. Non NAS models: Release throttle cable from abutment bracket and disconnect cable from throttle body cam.






15. Non NAS models: Disconnect cruise control actuator vacuum pipe.

CAUTION: Always fit plugs to open connections to prevent contamination.





16. NAS models: Depress locking collars and release vacuum/breather pipes from LH and RH camshaft covers and release pipe from clip.
17. NAS models: Remove clip securing vacuum/breather pipe to engine air intake hose and disconnect vacuum/breather pipe from air intake hose. Discard clip.

CAUTION: Always fit plugs to open connections to prevent contamination.

18. NAS models: Depress locking collars and release vacuum/breather pipe from LH camshaft cover, RH camshaft cover link pipe and inlet manifold chamber. Remove pipe.

CAUTION: Always fit plugs to open connections to prevent contamination.






19. NAS models: Disconnect multiplug from IAT and MAF sensors.
20. NAS models: Disconnect multiplug from throttle body.
21. NAS models: Remove clip securing intake hose to throttle body, remove intake hose and MAF sensor assembly. Discard clip.
22. NAS models: Release harness and fuel feed pipe from clip on inlet manifold chamber.






23. Disconnect multiplugs from VIS motors.






24. Remove 2 screws securing engine harness brackets to inlet manifold chamber and position harness aside.






25. Remove 2 bolts securing inlet manifold chamber rear support brackets to RH camshaft cover.





26.Remove 4 bolts securing inlet manifold chamber to LH inlet manifold.






27. Release 3 locking clips and disconnect 3 multiplugs from RH plug top coils.
28. Release and raise inlet manifold chamber from inlet manifolds.






29. Release 2 clips securing RH plug top coil harness to inlet manifold chamber support brackets.






30. Remove inlet manifold chamber.
31. Remove and discard seals from inlet manifold chamber and 'O' rings from RH inlet manifold.

Refit

1. Clean seal faces on inlet manifold chamber and inlet manifolds.
2. Fit new 'O' rings to RH inlet manifold and new seals to inlet manifold chamber.
3. Position inlet manifold chamber, secure RH coil harness clips in inlet manifold chamber support brackets.
4. Align inlet manifold chamber to inlet manifolds, fit and tighten bolts to 18 Nm (13 lbf ft).
5. Align inlet manifold chamber support brackets to RH camshaft cover, fit and tighten bolts to 10 Nm (7 lbf ft).
6. Connect multiplugs to plug top coils and secure with locking clips.
7. Position engine harness brackets to inlet manifold chamber, fit and tighten screws.
8. Connect multiplugs to VIS motors.
9. NAS models: Align harness and fuel feed pipe. Secure harness and pipe in clip on manifold chamber.
10. NAS models: Using a new clip, fit intake hose to throttle body and secure hose with clip.
11. NAS models: Connect multiplug to throttle body.
12. NAS models: Connect multiplugs to IAT and MAF sensors.
13. NAS models: Fit vacuum/breather pipe and connect to LH camshaft cover, RH camshaft cover link pipe and inlet manifold chamber.
14. NAS models: Using a new clip, fit vacuum/breather pipe to engine air intake hose and secure pipe with clip.
15. NAS models: Connect vacuum/breather pipe to LH and RH camshaft covers. Fit pipe into clip.
16. Non NAS models: Connect cruise control actuator vacuum pipe.
17. Non NAS models: Fit vacuum/breather pipe to throttle body and connect pipe to LH and RH camshaft covers.
18. Non NAS models: Fit vacuum/breather pipe to purge control valve and LH camshaft cover. Using a new clip, connect pipe to 'T' piece and secure pipe with clip.
19. Non NAS models: Connect multiplug to TP sensor.
20. Non NAS models: Connect multiplug to IACV.
21. Non NAS models: Connect vacuum pipe to IACV.
22. Non NAS models: Connect small vacuum pipe to purge control valve.
23. Connect multiplug to purge control valve .
24. Connect EVAP hose to purge control valve.
25. Connect fuel hose to fuel rail pipe, fit rubber sleeve over hose connector.
26. Non NAS models: Connect throttle inner cable to throttle cam and secure outer cable in abutment bracket.
27. Non NAS models: Secure throttle cable in clips on harness brackets.
28. Non NAS models: Adjust throttle cable. Adjustments
29. Fit vacuum enhancer. Service and Repair
30. Connect the battery earth lead.