Removal
1. Relieve residual fuel pressure.
2. Disconnect the battery.
3. Drain the coolant.
4. Remove the resonance chamber.
5. Remove the Venturi nozzle housing.
6. Disconnect the fuel temperature sensor and injector connectors.
7. Remove the fuel pressure regulator.
8. Disconnect the coolant temperature sensor connector (injection systems).
9. Disconnect the coolant temperature sensor connector (indicator on the instrument panel).
10. Disconnect the sensor wires from the clips.
11. Remove the upper thermostat housing hose.
12. Disconnect the ignition distributor connector.
13. Disconnect the heater tap hose.
14. Disconnect the injector wires from the fuel manifold clip and move them to the side.
15. Disconnect the fuel line from the fuel manifold.
Note: The intake manifold can be removed from the engine without removing the injectors.
16. Remove the 12 intake manifold mounting bolts in the order shown in the figure.
17. Remove the intake manifold.
18. Note the installation position and remove the intake manifold gasket mounting bolts and clips.
19. Remove the gasket.
20. Remove the seals from the gasket and discard them.
Note: Perform the following operations as needed.
21. Unscrew the 5 nuts securing the fuel manifold bracket to the intake manifold.
22. Remove the fuel manifold and injectors.
23. Unscrew the 2 thermostat mounting bolts.
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24. Remove the thermostat housing.
25. Unscrew the cooling system pipe mounting bolt, unscrew the pipe nut and remove the pipe. Remove the sealing ring from the tube.
26. Install a new sealing ring on the tube and secure the tube to the manifold.
27. Clean the thermostat mating surface.
28. Install the thermostat with a new gasket, tighten the mounting bolts.
29. Install the injectors and fuel manifold.
Installation
1. Clean the mating surfaces of the block, cylinder head and intake manifold.
2. Install new seals on the block and cylinder heads.
3. Apply RTV sealant to the ends of the seals.
4. Position the manifold gasket with the FRONT mark toward the front of the engine and the open bolt hole toward the right side.
5. Place the gasket clips and tighten the mounting bolts by hand.
6. Clean the threads of the bolts and the threaded holes for the manifold mounting bolts, install the manifold on the engine.
7. Allow the sealant to dry for 10 minutes.
8. Tighten the manifold mounting bolts by hand, then tighten the bolts to 38 N·m in the order shown in the figure.
Location of fuel lines
Note: Before removing the fuel line, relieve any residual fuel pressure in the system. Observe fire safety measures.
1 - fuel supply hose to the fuel manifold, 2 - fuel return hose to the tank, 3 - fuel supply pipe, 4 - fuel return pipe, 5 - fuel filter, 6 - fuel supply pipe to the filter, 7 - tank ventilation hose, 8 - fuel pump (in the tank), 9 - filler neck, 10 - fuel tank.
9. Tighten the gasket clip bolts to 18 Nm.
10. Reinstall the removed parts.
11. Start the engine and check for coolant and fuel leaks.
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