Gasket - Inlet Manifold - Lower

Gasket - Inlet Manifold - Lower

Remove
1. Remove both rocker covers.




2. Release and disconnect LH injector harness and multiplugs.




3. Release 3 clips securing top hose and remove top hose.
4. Remove auxiliary drive belt.




5. Remove 3 bolts securing Active Cornering Enhancement (ACE) pump, release pump and position aside.




6. Remove 2 bolts securing alternator and remove alternator.




7. Remove 3 bolts securing Power Assisted Steering (PAS) pump pulley and remove pulley.
8. Remove jockey pulley.
9. Position tray to catch spillage, release PAS pump high pressure pipe.

CAUTION: Always fit plugs to open connections to prevent contamination.




10. Remove bolt securing oil cooling pipe and release bracket from auxiliary housing.
11. Remove two bolts securing PAS pump.
12. Remove 5 bolts and one nut securing auxiliary housing. Pull housing forward, release PAS pump and remove housing.




13. Remove 4 bolts securing top hose outlet and remove outlet pipe.
14. Remove and discard 'O'-ring.
15. Position absorbent cloth to catch spillage.




16. Disconnect fuel pipe.

CAUTION: Always fit plugs to open connections to prevent contamination.




17. Using the sequence shown, remove 12 bolts securing the inlet manifold.
18. Remove inlet manifold.




19. Remove 2 bolts securing inlet manifold gasket and collect gasket clamps.
20. Remove inlet manifold gasket.
21. Remove gasket seals.


Refit
1. Clean old RTV sealant from cylinder head and cylinder block notches.
2. Clean mating faces of cylinder block, cylinder head and inlet manifold.
3. Apply RTV sealant to cylinder head and cylinder block notches.
4. Fit new gasket seals, ensuring ends engage correctly in notches.
5. Fit new inlet manifold gasket.
6. Position gasket clamps and fit bolts, but do not tighten at this stage.




7. Position inlet manifold to engine. Fit manifold bolts and, working in the sequence shown, tighten bolts initially to 10 Nm (7 ft. lbs.) then to 51 Nm (38 ft. lbs.).
8. Tighten gasket clamp bolts to 18 Nm (13 ft. lbs.).
9. Connect fuel pipe.
10. Clean top hose outlet pipe mating faces.
11. Fit new 'O' ring to outlet pipe.
12. Position outlet pipe, fit bolts and tighten to 22 Nm (16 ft. lbs.).
13. Position alternator, fit bolts and tighten to 45 Nm (33 ft. lbs.).
14. Position PAS pump to auxiliary housing and locate housing on engine. Fit bolts and tighten to 40 Nm (30 ft. lbs.).
15. Fit and tighten auxiliary housing nut to 10 Nm (7 ft. lbs.).
16. Fit bolts securing PAS pump and tighten to 22 Nm (16 ft. lbs.).
17. Position oil cooling pipe bracket fit bolt and tighten to 22 Nm (16 ft. lbs.).
18. Fit and tighten PAS pump high pressure pipe.
19. Position jockey pulley and tighten bolt to 50 Nm (37 ft. lbs.).
20. Clean PAS pump pulley mating faces.
21. Position PAS pump pulley, fit bolts and tighten to 22 Nm (16 ft. lbs.).
22. Clean ACE pump dowels and dowel holes.
23. Position ACE pump, fit bolts and tighten to 22 Nm (16 ft. lbs.).
24. Fit auxiliary drive belt.
25. Secure injector harness and connect injector multiplugs.
26. Position top hose and secure clips.
27. Fit rocker covers.
28. Check and top up PAS fluid