INTAKE MANIFOLD - R.R. and Replace gasket

Operation 1072B10 · Inlet manifolds

2.0 TB

Removing

- Position the vehicle on a lift.

- Make sure that the ignition key is in the OFF position, then open the boot, remove the cover on the left hand side and disconnect the negative battery lead.

See in Op. 7040D50 ENGINE COMPARTMENT UPPER SOUND INSULATION SHIELD - R.R.

See in Op. 1080D24 engine oil vapour intake pipe - r + r

See in Op. 1016A40 Ignition COIL COVER on cylinder head - R.R.

See in Op. 1048A50 air inlet pipe to turbocharger - r + r

See in Op. 1084A16 Engine oil dip stick PIPE - R.R.

See in Op. 7055B54 PROTECTION/GUARD under engine - R.R.

1. Disconnect the electrical connections for the ignition coils (1a), the injectors (1b), the engine management control unit (1c), the phase transformer solenoid (1d) and the throttle casing actuator (1e).

- Release the wiring from the fastening springs located on the chamber, the cylinder head and the fuel manifold and turn it over onto its side.

1. Undo the bolts (1a) and remove the tappet cover (1b) complete with gasket.

1. Undo the fixing bolt (1a) and move the turbocharger engine coolant return pipe (1b) away.

2. Release the fuel pipes from the band on the intake chamber.

3. Disconnect the pipe from the pressure regulator.

4. Undo the bolts (4a) and turn the fuel manifold assembly (4b) over.

1. Disconnect the pneumatic connections for the supercharging air by-pass valve (1a), the brake servo (1b) and the evaporation control circuit (rapid connector) (1c).

- Raise the lift.

1. Undo the fixing bolts (1a) and nuts (1b) and disconnect the earth lead (1c).

- Lower the lift.

2. Release the wiring from the springs and remove the chamber mounting bracket.

1. Undo the bolts fixing the intake chamber to the manifold.

2. Disconnect the band (2a) for the throttle casing air intake hose and the bands (2b) connecting the intake chamber to the hoses connected to the intake manifold.

3. Remove the intake chamber.

1. Undo the fixing bolt (1a) and the nuts (1b) and remove the intake manifold (1c), complete with hoses (1d) connected to the intake chamber and the throttle casing.

2. Remove the seal.

Refitting

- Position the intake manifold complete with a new seal and hoses connected to the intake chamber.

- Tighten the nuts and the bolt fixing the intake manifold to the cylinder head to the recommended torque.

- Fit the intake chamber ducts on the hoses connected to the intake manifold and secure them using the retaining bands.

- Position the air inlet hose on the throttle casing and secure it using the retaining band.

- Tighten the bolts fixing the intake chamber to the manifold.

- Positin the chamber mounting bracket on the vibration damper supports and secure it using the nuts.

- Raise the lift.

- Tighten the bolts fixing the bracket and fasten the earth lead.

- Lower the lift.

- Connect the pneumatic connections for the supercharging air by-pass valve, the brake servo and the evaporation control circuit (rapid connector).

- Position the fuel manifold complete with injectors and secure it using the fixing bolts.

- Connect the pipe to the pressure regulator.

- Secure the fuel pipes to the springs.

- Position the coolant return pipe on the retaining springs and tighten the fixing bolt.

- Fit the tappet cover positioning the gasket and tighten the fixing bolts.

- Connect the electrical connections for the injectors.

- Connect the electrical connections for the ignition coils.

- Connect the electrical connections for the injection control unit, the integrated throttle casing actuator and the phase transformer actuator.

- Secure the engine wiring to the retaining bands on the intake chamber, the cylinder head and the fuel manifold.

See in Op. 1080D24 engine oil vapour intake pipe - r + r

See in Op. 1016A40 Ignition COIL COVER on cylinder head - R.R.

See in Op. 1048A50 air inlet pipe to turbocharger - r + r

See in Op. 1084A16 Engine oil dip stick PIPE - R.R.

See in Op. 7055B54 PROTECTION/GUARD under engine - R.R.

See in Op. 7040D50 ENGINE COMPARTMENT UPPER SOUND INSULATION SHIELD - R.R.

- Connect the negative battery terminal, then close the boot.

- Remove the vehicle from the lift.

2.4 20V

Removing

- Position the vehicle on a lift.

- Open the boot, remove the cover on the left hand side and disconnect the negative battery lead.

- Raise the vehicle on the lift.

See in Op. 7040D50 ENGINE COMPARTMENT UPPER SOUND INSULATION SHIELD - R.R.

See in Op. 7055B54 PROTECTION/GUARD under engine - R.R.

See in Op. 1016A40 Ignition COIL COVER on cylinder head - R.R.

See in Op. 1048A28 vacuum air circuit resonator pipe - r+r

See in Op. 1048A48 HOSE BETWEEN RESONATOR AND THROTTLE CASING - R.R.

See in Op. 1056B82 Injection/ignition system CONTROL UNIT (one) - R.R.

See in Op. 1056B14 THROTTLE CASING - R.R.

See in Op. 1056B87 INJECTION/IGNITION CONTROL UNIT MOUNTING - R.R.

1. Disconnect the electrical connections for the ignition coils (1a), the injectors (1b) and the phase transformer solenoid (1c); release the wiring from the retaining bands.

2. Disconnect the connectors for the front Lambda sensor (2a), the rear Lambda sensor (2b) and the air conditioning compressor coupling.

3. Disconnect the earth lead, then release the engine wiring from the retaining bands on the intake chamber and place it to the side.

- Disconnect the electrical connection for the coolant temperature sensor.

- Discharge the fuel pressure with the tool connected to the valve on the single fuel manifold pipe.

1. Disconnect the fuel supply pipe from the manifold.

2. Disconnect the oil vapour recovery pipe from the tappet cover.

3. Disconnect the fuel vapour recovery pipe.

- Disconnect the electrical connection (1a) for the left detonation sensor and the electrical connection (1b) for the rpm sensor on the intake chamber, then undo the bolts fixing the connector; release the wiring from the retaining bands.

1. Disconnect the electrical connection (1a) for the timing sensor and the connector (1b) for the right detonation sensor on the intake chamber, then undo the bolts fixing the connectors.

2. Undo the bolt fixing the engine oil dipstick pipe.

1. Undo the bolt (1a), loosen the bolt (1b) and rotate the reaction rod connecting rod.

1. Undo the bolt (1a), open the retaining brackets (1b) and remove the engine coolant recovery pipe (1c).

- Undo the three fixing bolts (1a) and remove the fuel manifold (1b) complete with injectors.

- Raise the vehicle.

1. Undo the nut fixing the intake chamber to the mounting bracket.

- Release the wiring from the mounting bracket.

- Lower the vehicle on the lift.

1. Undo the bolt fixing the intake chamber to the manifold.

1. Disconnect the bands joining the intake chamber to the hoses connected to the intake manifold, then release the chamber from the hoses.

1. Undo the fixing nuts (1a) and the bolt (1b) and remove the intake manifold (1c), complete with hoses (1d) connected to the intake chamber and the phase transformer solenoid (1d).

2. Remove the seal.

Refitting

- Position the intake manifold complete with a new seal and hoses connected to the intake chamber.

- Tighten the nuts and the bolt fixing the intake manifold to the cylinder head to the recommended torque.

- Fit the intake chamber ducts on the hoses connected to the intake manifold and secure them using the retaining bands.

- Tighten the bolt fixing the intake chamber to the manifold.

- Raise the vehicle on the lift.

- Tighten the nut fixing the intake chamber to the mounting bracket.

- Lower the vehicle on the lift.

- Position the fuel manifold complete with injectors and secure it using the fixing bolts.

- Connect the connecting rod to the reaction rod and secure it using the bolts.

- Tighten the bolt fixing the engine oil dipstick pipe.

See in Op. 1056B87 INJECTION/IGNITION CONTROL UNIT MOUNTING - R.R.

See in Op. 1056B14 THROTTLE CASING - R.R.

See in Op. 1056B82 Injection/ignition system CONTROL UNIT (one) - R.R.

- Connect the electrical connections for the injectors.

- Connect the electrical connection for the phase transformer solenoid.

- Connect the electrical connections for the ignition coils.

- Connect the electrical connections for the front Lambda sensor, the rear Lambda sensor and the air conditioning compressor coupling.

- Connect the electrical connection for the coolant temperature sensor.

- Connect the earth lead on the cylinder head.

- Secure the engine wiring to the retaining bands on the intake chamber.

- Connect the fuel supply pipe to the manifold.

- Connect the fuel vapour recovery pipe.

- Connect the oil vapour recovery pipe to the tappet cover.

- Connect the electrical connection for the left detonation sensor and the electrical connection for the rpm sensor to the intake chamber; secure the wiring to the retaining bands.

- Connect the electrical connection for the timing sensor and the electrical connector for the right detonation sensor to the intake chamber.

- Position the rigid coolant recovery pipe and secure it using the bolt and the retaining brackets.

See in Op. 1048A48 HOSE BETWEEN RESONATOR AND THROTTLE CASING - R.R.

See in Op. 1048A28 vacuum air circuit resonator pipe - r+r

See in Op. 1016A40 Ignition COIL COVER on cylinder head - R.R.

See in Op. 7055B54 PROTECTION/GUARD under engine - R.R.

See in Op. 7040D50 ENGINE COMPARTMENT UPPER SOUND INSULATION SHIELD - R.R.

- Connect the negative battery lead, then close the boot.

- Remove the vehicle from the lift.

2.4 JTD 10V

Removing

- Position the vehicle on a lift.

- Open the boot and disconnect the negative battery terminal.

See in Op. 1016A10

See in Op. 7055B54 PROTECTION/GUARD under engine - R.R.

See in Op. 4450B04 Right FRONT WHEEL (one) - R.R.

See in Op. 7055B42 FRONT WHEEL ARCH LINER (one), left or right - R.R.

See in Op. 7055B64 Engine compartment DUST SEAL in front wheel arch (one), left or right - R.R.

See in Op. 1092G10

See in Op. 1032D12

See in Op. 1032B10

See in Op. 1060E30

See in Op. 1060F20

See in Op. 1060F36

See in Op. 1060F30

See in Op. 1060E10

See in Op. 1048A21

1. Disconnect the electrical connection for the throttle casing pneumatic solenoid valve.

2. Undo the fixing nuts (2a), disconnect the pipe connecting the pneumatic valve vacuum reservoir (2b) and remove the vacuum reservoir (2c).

1. Undo the fixing bolts.

2. Remove the vacuum reservoir mounting bracket.

3. Remove the stud fixing the pressure pump to the pressure pump mounting.

1. Undo the fixing nuts.

2. Disconnect the electrical connection for the fuel pressure sensor.

3. Remove the single fuel manifold pipe.

1. Undo the fixing bolts.

2. Disconnect the flexible pipe (2a) from the turbocharger vanes actuator solenoid valve, then remove the rigid section (2b) of the pipe connecting the vacuum reservoir and solenoid valve.

1. Disconnect the electrical connections (1a), (1b), (1c), (1d) and (1e).

2. Undo the fixing bolts (2a) and remove the injection wiring (2b) from the work area.

3. Undo the bolts (3a) and remove the bracket connecting the intake manifold and the pressure pump mounting (3b).

1. Undo the bolts (1a) fixing the EGR supply pipe (1b) to the exhaust pipe.

1. Undo the bolts fixing the exhaust gas supply to the EGR solenoid valve.

2. Undo the bolts fixing the exhaust gas supply pipe mounting bracket to the cylinder head.

1. Undo the nut (1a) fixing the exhaust gas supply pipe to the thermostat stud (1b).

2. Move the exhaust gas supply pipe away from the housing in order to facilitate the subsequent removal of the intake manifold.

1. Undo the fixing nuts (1a) and remove the intake manifold (1b) from the cylinder head.

2. Remove the intake manifold gasket from the studs.

Refitting

- Fit the new intake manifold gasket on the cylinder head studs.

- Fit the intake manifold in the housing on the cylinder head.

- Tighten the nuts fixing the intake manifold to the cylinder head.

- Position the exhaust gas supply pipe to the EGR in the housing.

- Tighten the bolts fixing the front section of the exhaust gas supply pipe to the exhaust manifold.

- Tighten the bolts fixing the rear section of the exhaust gas supply pipe to the EGR valve.

- Tighten the bolts fixing the exhaust gas supply pipe bracket to the cylinder head.

- Fit the bracket connecting the intake manifold to the pressure pump mounting.

- Position the injection wiring and connect the electrical connections disconnected previously.

- Fit the rigid section of the ipe connecting the solenoid valve to the vacuum reservoir and secure it using the bolts.

- Connect the flexible section of the turbocharger vacuum pipe to the rigid pipe.

- Position the single fuel manifold in the special housing on the intake manifold.

- Tighten the nuts fixing the fuel manifold to torque.

- Connect the electrical connection for the fuel pressure sensor.

- Fit the vacuum reservoir mounting bracket.

- Tighten the stud fixing the pressure pump in the special housing.

- Fit the vacuum reservoir on the mounting and tighten the fixing bolts.

- Connect the connecting pipes to the pneumatic valve.

- Connect the electrical connection for the solenoid valve.

See in Op. 1048A21

See in Op. 1060E10

See in Op. 1060F30

See in Op. 1060F36

See in Op. 1060F20

See in Op. 1060E30

See in Op. 1032B10

See in Op. 1032D12

See in Op. 1092G10

See in Op. 7055B64 Engine compartment DUST SEAL in front wheel arch (one), left or right - R.R.

See in Op. 7055B42 FRONT WHEEL ARCH LINER (one), left or right - R.R.

See in Op. 4450B04 Right FRONT WHEEL (one) - R.R.

See in Op. 7055B54 PROTECTION/GUARD under engine - R.R.

See in Op. 1016A10

- Open the boot and connect the negative battery terminal.

- Remove the vehicle from the lift.

2.4 JTD 20V

Removing

- Position the vehicle on a lift.

- Open the boot and disconnect the negative battery terminal.

See in Op. 7055B54 PROTECTION/GUARD under engine - R.R.

See in Op. 4450B04 Right FRONT WHEEL (one) - R.R.

See in Op. 7055B42 FRONT WHEEL ARCH LINER (one), left or right - R.R.

See in Op. 7055B64 Engine compartment DUST SEAL in front wheel arch (one), left or right - R.R.

See in Op. 1016A10 SOUND-PROOFING COVER - R.R.

See in Op. 7040D50 ENGINE COMPARTMENT UPPER SOUND INSULATION SHIELD - R.R.

See in Op. 1048B44 RIGID air supply PIPE from heat exchanger to intake manifold - R.R.

See in Op. 1048A56 UPPER RESONATOR - R.R.

See in Op. 1092G10 Engine components single drive BELT - R.R.

See in Op. 1092G21 Engine components single belt FIXED TENSIONER - R.R. with belt removed

See in Op. 1092A10 Crankshaft PULLEY - R.R.

See in Op. 1032D12 Timing system protective COVER(S) - R.R.

See in Op. 1032B10 TOOTHED timing BELT - R.R. for timing adjustment or replacement

See in Op. 1060E30 PRESSURE PUMP drive PULLEY - R.R.

See in Op. 1060E10 PRESSURE PUMP for diesel injection - R.R.

1. Disconnect the vacuum pipe from the brake servo vacuum pipe (1a), from the pneumatic valve on the throttle casing (1b) and from the rigid section connected to the variable geometry solenoid valve (1c).

2. Disconnect the electrical connection for the solenoid valve on the vacuum reservoir.

- Release the vacuum pipes from the retaining bands.

3. Undo the nuts fixing the vacuum reservoir to the mounting bracket.

4. Remove the vacuum reservoir.

1. Undo the engine oil vapour separator mounting bracket fixing bolts.

1. Disconnect the oil vapour pipe from the filler (1a), from the separator (1b) and from the retaining band (1c).

2. Remove the engine oil vapour pipe.

1. Disconnect the electrical connection from the heater plugs control unit.

1. Disconnect the EGR electrical connection.

2. Undo the bolts securing the EGR pipe to the heat exchanger.

3. Undo the bolts fixing the EGR valve to the intake manifold.

4. Remove the EGR solenoid valve.

1. Disconnect the flexible section of the vacuum pipe from the rigid section.

2. Undo the retaining bolts.

3. Remove the rigid vacuum pipe.

- Disconnect the absolute pressure sensor.

1. Disconnect the flexible sections of the water recirculation pipe from the thermostat and from the cylinder head.

2. Undo the retaining bolts.

3. Remove the water recirculation pipe.

- Raise the lift.

1. Undo the lower bolt securing the engine oil dipstick tube.

- Lower the lift.

2. Undo the upper bolt securing the engine oil dipstick tube.

3. Release the coupling for the engine wiring from the fastening on the pipe, then remove the engine oil dipstick pipe from the top part of the engine compartment.

1. Undo the bolts fixing the power assisted steering pump and move it from its housing retracting it.

1. Undo the two retaining bolts (1a) and remove the power assisted steering pump guard (1b).

1. Undo retaining bolts (1a) and remove bracket (1b).

1. Undo the retaining bolts.

2. Remove the pressure pump support.

1. Undo the nuts securing the intake manifold to the cylinder head.

2. Remove the intake manifold.

- Recover the underlying gasket.

Refitting

1. Fit the intake manifold (1a), complete with gasket and secure it tightening the nuts (1b) to the recommended torque.

1. Fit the pressure pump mounting (1a) and secure it using the bolts (1b).

- Fit the bracket joining the intake manifold and the cylinder head and tighten the fixing bolts.

- Fit the power assisted steering pump guard and tighten the retaining bolts.

1. Position the power assisted steering pump in its housing and secure it tightening the bolts to the recommended torque.

- Fit the oil dipstick pipe, raise the lift and tighten the lower fixing bolt on the oil sump.

- Lower the vehicle and tighten the upper fixing bolt.

- Press fit the coupling for the engine wiring on the engine oil dipstick pipe.

- Fit the rigid water recirculation pipe and connect it to the flexible sections on the head and on the thermostat.

- Tighten the bolts fixing the recirculation pipe to the intake manifold.

- Fit the rigid vacuum pipe, tighten the fixing bolts and also connect the variable geometry solenoid valve flexible vacuum pipe to it.

- Fit the E.G.R. system solenoid valve (1a) complete with gasket and secure it tightening the bolts to the recommended torque.

- Tighten the bolts fixing the exhaust gas recirculation pipe to the EGR solenoid valve to torque.

- Connect the EGR electrical connection.

- Connect the electrical connection to the heater plugs control unit.

- Fit the engine oil vapour pipe and connect it to the filler and to the separator.

- Tighten the bolts fixing the engine oil vapour separator mounting bracket to the intake manifold.

- Fit the vacuum reservoir and tighten the fixing nuts to the mounting bracket.

- Connect the electrical connection for the solenoid valve on the vacuum reservoir.

- Connect the vacuum pipe to the brake servo vacuum pipe, to the pneumatic valve on the throttle casing and to the rigid section connected to the variable geometry solenoid valve.

- Fasten it to the engine using the plastic bands opened previously.

See in Op. 1060E10 PRESSURE PUMP for diesel injection - R.R.

See in Op. 1060E30 PRESSURE PUMP drive PULLEY - R.R.

See in Op. 1032B10 TOOTHED timing BELT - R.R. for timing adjustment or replacement

See in Op. 1032D12 Timing system protective COVER(S) - R.R.

See in Op. 1092A10 Crankshaft PULLEY - R.R.

See in Op. 1092G21 Engine components single belt FIXED TENSIONER - R.R. with belt removed

See in Op. 1092G10 Engine components single drive BELT - R.R.

See in Op. 1048A56 UPPER RESONATOR - R.R.

See in Op. 1048B44 RIGID air supply PIPE from heat exchanger to intake manifold - R.R.

See in Op. 7040D50 ENGINE COMPARTMENT UPPER SOUND INSULATION SHIELD - R.R.

See in Op. 1016A10 SOUND-PROOFING COVER - R.R.

See in Op. 7055B64 Engine compartment DUST SEAL in front wheel arch (one), left or right - R.R.

See in Op. 7055B42 FRONT WHEEL ARCH LINER (one), left or right - R.R.

See in Op. 7055B54 PROTECTION/GUARD under engine - R.R.

See in Op. 4450B04 Right FRONT WHEEL (one) - R.R.

- Top up the engine coolant, following the instructions in the description:

See in Op. 0010T21 ENGINE COOLANT - Check density and top up if necessary

- Connect the negative battery terminal.

- Remove the vehicle from the lift.