Inlet pipeline (E7J engines)
Removing
1. Remove the throttle body as described in Section Removal and installation of the throttle body.
2. Drain the liquid from the cooling system as described in Chapter Maintenance, then disconnect the coolant hoses from the intake manifold.
3. Disconnect the brake booster vacuum hose and wiring connector from the heater at the bottom of the intake manifold.
4. Gradually turn away nuts, then remove the inlet pipeline from hairpins in a head of the block of cylinders. Remove the gasket.
5. If necessary, the heater can be removed from the base of the intake manifold (2), by removing the retaining ring (1). Note the location of the seal (3) (refer to accompanying illustration).
Installation
1. Install in reverse order. Use a new gasket and tighten the fixing nuts to Specifications effort. Fill the cooling system as described in Chapter Maintenance.
Inlet pipeline (K7M engines)
Removing
1. Remove the fuel line and injector assembly as described in Section Removal and installation of components of system of the distributed injection. Also disconnect the fuel pressure regulator hose from the right end of the intake manifold (refer to accompanying illustration).
2. Remove the intake air duct as described in Section Removal and installation - air filter assembly and intake ducts. To improve access, engage the handbrake, then jack the front end up on axle stands. Where applicable, remove the engine bottom shield.
3. Remove the throttle body as described in Section Removal and installation of the throttle body. Move the fuel supply and return hoses to the side and plug them to prevent loss of fuel.
4. Where applicable, disconnect the wiring from the EGR valve, then remove the bolts and valve. Release the bracket, then unscrew the steel tube from the EGR valve.
5. Remove the bolts securing the harness bracket to the back of the intake manifold.
6. Disconnect the vacuum hose of the absolute pressure in the pipeline and the vacuum hose of the brake booster.
7. Disconnect the EVAP solenoid valve hoses.
8a. Loosen the bottom nuts.
8b. Turn away bolts of the top fastening.
8c. Then carefully remove the intake manifold from the studs and remove the gasket (refer to illustrations).
Installation
1. Install in reverse order, use a new gasket and tighten the mounting nuts and bolts to Specifications effort. Make sure that the contact surfaces of the cylinder head and pipeline are clean.
Inlet pipeline (F3R engines)
Removing
1. Remove the fuel line and injector assembly as described in Section Removal and installation of components of system of the distributed injection.
2. Apply the handbrake, then jack up the front of the vehicle and place it on axle stands. Where applicable, remove the engine bottom shield.
3. Disconnect the exhaust system from the manifold as described in Section Removing and installing the exhaust system.
4. Turn away bolts of fastening and remove a heat-insulating board over a starter.
5. Loosen and remove all bottom pipe mounting nuts.
6. From above, disconnect the brake booster vacuum hose, line pressure sensor hose, vacuum hose and breather hose from the pipeline.
7. Loosen and remove the top pipe mounting nuts, then separate the intake pipe from the engine.
8. Remove the exhaust manifold and remove the gasket, noting its location.
Installation
1. Install in reverse order. Use a new gasket and tighten the mounting nuts and bolts to Specifications effort. Make sure the contact surfaces of the cylinder head and manifold are clean.
Inlet pipeline (F7R engines)
Removing
1. Remove the throttle body as described in Section Removal and installation of the throttle body.
2. Remove the fuel line and injector assembly as described in Section Removal and installation of components of system of the distributed injection.
3. Disconnect the steel pipe under the exhaust gas recirculation valve and release the electrical wiring under the pipeline from the fixtures.
4. Release the reservoir of the power steering hydraulic system from the mounting and move it to the side.
5. Unscrew the supports below the pipeline and remove the bolt securing the dipstick tube to the support.
6. Disconnect the vacuum hoses of the brake booster, the EGR solenoid valve and the pressure sensor in the pipeline.
7. Remove the generator bracket from the pipeline.
8. Turn away nine fixing nuts and remove the pipeline from the engine.
Installation
1. Install in reverse order. Use a new gasket and tighten the mounting nuts and bolts to Specifications effort. Make sure the contact surfaces of the cylinder head and manifold are clean.
An exhaust manifold
Note. On models with the F3R engine, the removal of the exhaust manifold is part of the intake manifold removal procedure described earlier in this Section.
Removing
1. Apply the handbrake, then jack up the front of the vehicle and place it on axle stands. Where applicable, remove the engine bottom shield.
2. On the E7J engine, disconnect the warm air hose from the shroud on the exhaust manifold.
3. Loosen the nuts/bolts and remove the air heater chamber and, where applicable, heat shields from the manifold (refer to accompanying illustration).
4. Support downpipe where necessary (do not damage the lambda sensor), then remove the nuts/bolts securing the muffler/converter downpipe to the exhaust manifold. Remove gasket (refer to accompanying illustration).
5. Where applicable, remove the nut and release the brackets holding the EGR valve steel pipe to the manifold.
6a. Loosen the fixing nuts.
6b. Remove the exhaust manifold from the studs on the cylinder head (refer to the illustrations.
7. Remove gasket (refer to accompanying illustration).
Installation
1. Install in reverse order. Tighten the nuts given in Specifications effort. Make sure the contact surfaces of the cylinder head and manifold are clean and use a new gasket.