Intake and Exhaust Manifolds

REMOVAL
1. Remove intake air temperature sensor.





2. Remove Manifold Absolute Pressure (MAP) sensor mounting screws.
3. Remove Manifold Absolute Pressure (MAP) sensor.





4. Remove intake manifold stay.
5. Remove EGR tube fasteners from the intake manifold and valve. Remove tube from engine.
6. Remove vacuum hose and electrical connection from intake manifold.
7. Remove attaching screws from engine and remove intake manifold from engine.

INSTALLATION





1. Install new manifold gasket. DO NOT APPLY SEALER.
2. Set manifold in place. Tighten retaining fasteners, starting at center and progressing outward in both directions to 23 Nm (17 ft. lbs.). Repeat this procedure until all fasteners are at specified torque.
3. Install vacuum hose and electrical connection from intake manifold.
4. Install new EGR tube gaskets at the intake manifold and valve.
5. Install EGR tube and tighten fasteners to 8 Nm (6 ft. lbs.).
6. Install intake manifold stay.





7. Insert sensor into intake manifold while making sure not to damage O-ring seals.
8. Tighten mounting screws to 2 Nm (1.4 ft. lbs.) torque.
9. Install manifold air temperature sensor. Tighten sensor to 7 Nm (5 ft. lbs.) torque.


CLEANING AND INSPECTION
1. Discard gasket and clean gasket surfaces of manifold.
2. Test manifold gasket surfaces for flatness with straight edge. Surface must be flat within 0.15 mm per 300 mm of manifold length.
3. Inspect manifold for cracks or distortion. Replace manifold if necessary.