Contents: Disassembly ⇩ Assembly ⇩
Disassembly
1. Unscrew the nut securing the "positive" contact to the bracket on the cylinder head and remove the contact from the bracket.
2. Disconnect the vacuum hose from the afterburner control valve.
CAUTION: Always plug the fittings and holes to protect the system from dirt.
3. Disconnect the vacuum hose of the afterburning system from the rear cover of the intake manifold, remove the vacuum receiver and vacuum switch from the intake manifold, having previously marked their position.
CAUTION: Always plug the fittings and holes to protect the system from dirt.
4. Unscrew the 2 bolts securing the crankcase ventilation oil separator to the bracket on the intake manifold and move the oil separator to the side.
5. Loosen the clamp and remove the crankcase ventilation hose from the rear cover of the intake manifold.
CAUTION: Always plug the fittings and holes to protect the system from dirt.
6. Loosen the clamp and disconnect the crankcase ventilation hose from the valve cover.
CAUTION: Always plug the fittings and holes to protect the system from dirt.
7. Disconnect the purge valve hose from the intake manifold.
CAUTION: Always plug the fittings and holes to protect the system from dirt.
8. Unscrew the 10 nuts securing the intake manifold to the cylinder heads and remove the 10 spacer bushings.
9. Lift the intake manifold to gain access to the manifold drain hose.
10. Loosen the clamp and disconnect the drain hose from the intake manifold. Discard the clamp.
CAUTION: Always plug the fittings and holes to protect the system from dirt.
11. Remove the intake manifold and discard the 4 gaskets.
Assembly
1. Install new gaskets on the intake manifold.
2. Place the drain hose over the heads and secure the hose with a new clamp.
3. Place the intake manifold on the studs, install the spacers, tighten the nuts evenly and consistently to a torque of 10 Nm.
4. Connect the purge valve hose to the intake manifold.
5. Install the crankcase ventilation hoses and secure them with clamps.
6. Install the crankcase ventilation oil separator to the bracket and tighten the bolts to 6 N·m.
7. Install the afterburner vacuum switch and vacuum receiver on the intake manifold, connect the hoses to the rear cover of the intake manifold.
8. Connect the vacuum to the electromagnetic valve of the afterburning system.
9. Place the "positive" terminal on the intake manifold bracket and tighten the nut. Tightening torque 10 Nm.
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