Engine 2.0 l
Removal and installation
1. Disconnect the battery from ground. Drain the coolant and disconnect the radiator hose from the thermostat housing.
2. Remove the carburetor, marking all disconnected hoses and wires.
3. Disconnect all vacuum hoses from the manifold.
4. Unscrew the nuts, lubricating them with penetrating liquid. Move the manifold with light blows and remove.
5. Clean the separating surfaces of the manifold and cylinder head. Check the deformation of the planes, if necessary, grind the plane of the head (removing it) and replace the manifold.
6. Installation is carried out in reverse order. Replace the gasket. Tighten the manifold nuts to 22 Nm.
2.4L Engine
2.4L Engine Intake Manifold
1. Air vent; 2. Ventilation hose; 3. Inlet pipe; 4. Pipe; 5. Throttle and kick-down control cables; 6. Throttle body; 7. Gasket; 8. Crankcase ventilation hose; 9. Brake booster hose; 10. Vacuum hose; 11. Wire; 12. Coil; 13. Equalization chamber; 14. Collector
Removal and installation
1. Perform decompression. To do this, disconnect the connector at the rear of the fuel tank, start the engine and after it stops, turn off the ignition.
2. Disconnect the battery from ground. Drain the coolant and disconnect the radiator hose from the thermostat housing.
3. Mark and disconnect all hoses and wires from the manifold. Carefully disconnect and plug the fuel lines.
4. Disconnect the coil wire from the ignition distributor.
5. Remove the equalizing chamber.
6. Remove the fuel distributor with injectors.
7. Remove the ignition distributor.
8. Loosen the nuts and bolts and remove the manifold.
9. Clean the separating surfaces of the manifold and cylinder head.
10. Installation is carried out in reverse order. Replace manifold and equalization chamber gaskets. Tighten the manifold nuts to 16 Nm, starting with the nut in the middle of the manifold. Make the necessary adjustments.
2.6L Engine
2.6L Engine Intake Manifold
1. Filter; 2. Carburetor; 3. Gasket; 4. Upper radiator hose; 5. Liquid bypass hose; 6. Connecting hose; 7. Heater hose; 8. Brake booster hose; 9. Vacuum hose; 10. Air conditioner temperature sensor wire; 11. Temperature sensor wire; 12. Temperature indicator wire; 13. Collector; 14. Gasket
Removal and installation
1. Disconnect the battery from ground. Remove the air filter.
2. Drain the coolant and disconnect the radiator hose from the thermostat housing.
3. Remove the carburetor.
4. Remove the outlet pipe, thermostat and gasket.
5. Remove the secondary air filter and pipe.
6. Remove the oil level indicator.
7. Remove the air conditioning compressor. Move the unit to the side without disconnecting it from the line and secure it. Remove the compressor bracket.
8. Mark and disconnect all hoses and wires from the manifold and thermostat.
Carefully disconnect and plug the fuel lines. Move aside any wiring and hoses that interfere with manifold removal.
9. Remove the recirculation valve.
10. Unscrew the nuts and remove the manifold.
11. Clean the separating surfaces of the manifold and cylinder head. Check the deformation of the planes, if necessary, grind the plane of the head (removing it) and replace the manifold. Install all sensors and valves on the new manifold.
12. Installation is carried out in reverse order. Replace all gaskets and seals. Tighten the manifold nuts first by hand and then to 22 Nm, starting with the nut in the middle of the manifold. Tighten the compressor bracket bolts to 45 Nm, the compressor to 24 Nm, and the thermostat to 12 Nm. Check the operation of all sensors and indicator lights on the instrument panel.
Engines 3.0 and 3.5 l
3.0L Engine Surge Chamber
1. Air vent; 2. Accelerator cable adjustment bolts; 3. Throttle cable; 4. Accelerator cable; 5, 8. Vacuum hose; 6. Brake booster hose; 7. Recirculation valve temperature sensor connector; 9. Recirculation tube bolts; 10, 16, 20, 22. Gaskets; 11. Coil wire; 12. Coil; 13. Filler neck bracket; 14. Ventilation hose; 15. throttle body; 17, 18. Bolts and nuts; 19. Equalization chamber; 21. Recirculation valve; 23, 24. Racks
3.0L Engine Intake Manifold - Parts to Remove
N – parts subject to replacement during assembly; 1. High pressure fuel line; 2. Return fuel line; 3. Vacuum hose; 4. Engine control wiring connector; 5. Pipe, distributor and pressure regulator; 6. Vacuum wiring; 7. Liquid temperature gauge sensor connector; 8. Air Conditioner Fluid Temperature Sensor Connector; 9. Engine Management System Fluid Temperature Sensor Connector; 10. Thermal switch connector; 11. Upper radiator hose; 12. Bypass hose; 13. Heater pipe mounting bolts; 14, 16, 18. Gaskets; 15. Collector; 17. Outlet pipe; 19. Thermostat; 20. Air conditioner thermostat switch; 21. Control system fluid temperature sensor; 22. Thermal switch; 23. Liquid temperature indicator sensor; 24. Thermovalve
3.5L Engine Surge Chamber
1. Lid; 2. Switching block; 3. Vacuum tube A; 4. Vacuum hose A; 5. Receiver; 6. Suction valve solenoid; 7. Bracket; 8. Vacuum tube B; 9. Vacuum hose B; 10. Bracket; 11, 12, 13. Brackets of the equalizing chamber; 14–18. Recirculation system details (valve, sensor, tube and gaskets); 19. Throttle body; 20. Gasket; 22. Equalization chamber; 23. Upper section; 24, 25, 26. Gaskets
3.5L Engine Intake Manifold
N – parts subject to replacement during assembly; 1. Injector wires; 2. Fuel distributor with injectors; 3, 6. Isolator; 4. Pressure regulator; 5, 9,12. Ring; 7. Bracket; 8. Nozzles; 10. Seal; 11. Fuel pipeline; 14. Fuel distributor; 15. Collector; 16. Liquid temperature indicator sensor; 17. Control system fluid temperature sensor; 18, 19. Hoses; 20–22. Exhaust pipes; 23. Inlet manifold; 24. Thermostat; 25. Body; 26. Gasket
Removal and installation
1. Perform decompression. To do this, disconnect the connector at the rear of the fuel tank, start the engine and after it stops, turn off the ignition.
2. Disconnect the battery from ground. Drain the coolant.
3. Disconnect the air duct.
4. Loosen the accelerator adjustment bolts.
5. Mark and disconnect all accessible hoses and wires from the manifold.
6. Disconnect the coil wire from the ignition distributor.
7. Remove the coil.
8. Remove the throttle body and set it aside (do not disconnect the cooling system hoses from the branch pipe). Remember the location of the pipe mounting bolts.
Remove the gasket.
9. Unscrew the upper strut bolts, the equalizing chamber mounting bolts and remove the chamber and gasket.
10. Remove the racks.
11. Disconnect both fuel lines and vacuum hoses, remove the fuel distributor. Disconnect any remaining hoses that are now accessible (radiator hose, bypass hose and vacuum line).
12. Unscrew the bolts and remove the manifold chamber with the gasket.
13. Clean the separating surfaces of the manifold chambers and cylinder head. Check the deformation of the planes; if the deviation from the plane exceeds 0.3 mm, replace the manifold and transfer all sensors and valves to the new manifold.
14. Installation is carried out in reverse order. Replace all gaskets (do not lubricate with sealant) and seals. Tighten all connections to the specified torques.