Gasket - Inlet Manifold

Gasket - Inlet Manifold

Service Repair No - 30.15.08.01

Disassembly





1. Disconnect multiplug from coolant thermistor.
2. Disconnect multiplugs from injectors; release injector harness from fuel rail and position aside.





3. Remove 3 bolts securing Power Assisted Steering (PAS) pump pulley and remove pulley.
4. Loosen bolt securing jockey pulley and remove pulley.





5. Remove 4 bolts and one nut securing auxiliary housing and remove housing.
6. Remove 2 nuts securing alternator cables and release the cables.





7. Remove two bolts securing alternator and remove alternator.
8. Remove 4 bolts securing coolant outlet elbow and remove outlet elbow.
9. Remove and discard O-ring.
10. Release HT leads from rocker covers.





11. Remove 4 bolts securing rocker cover and remove cover.
12. Remove and discard rocker cover gaskets.




13. Using the sequence shown, remove 12 bolts securing the inlet manifold.
14. Remove inlet manifold assembly.





15. Remove 2 bolts securing manifold gasket and collect gasket clamps.
16. Remove inlet manifold gasket.
17. Remove gasket seals.

Reassembly

1. Clean sealant from cylinder head and from notches in the cylinder block.
2. Clean mating faces of cylinder block, cylinder head and manifold.

CAUTION: Do not use a metal scraper or machined surfaces may be damaged.

3. Apply sealant, Part No. STC 3254 to cylinder head and notches in cylinder block.
4. Fit new gasket seals, ensuring the ends engage correctly in notches.
5. Apply sealant, Part No. STC 3254 to gasket seals above the notches in the cylinder block.
6. Fit new manifold gasket, dry.
7. Position gasket clamps, fit and lightly tighten bolts.
8. Position inlet manifold assembly to cylinder head.





9. Fit manifold bolts and, working in the sequence illustrated, tighten as follows:
^ Initially, tighten bolts numbered 1, 4, 9 and 12 in numerical order to 5 Nm (41bf. ft).
^ Inlet manifold bolts - initial tighten = 10 Nm (8 ft. lbs.).
^ Inlet manifold bolts - final tighten = 51 Nm (38 ft. lbs.).
^ Tighten inlet manifold gasket clamp bolts to 18 Nm (14 ft. lbs.).
^ Tighten inlet manifold bolts to 51 Nm (38 ft. lbs.)
10. Clean mating faces of rocker covers and cylinder heads.
11. Fit new rocker cover gaskets, dry, position rocker cover, fit bolts and, working in a diagonal sequence tighten initially to 4 Nm (3 ft. lbs.) and finally to 8 Nm (6 ft. lbs.).
12. Secure HT leads to rocker cover.
13. Clean coolant outlet elbow mating faces.
14. Lubricate and fit new O-ring to outlet pipe.
15. Position coolant outlet elbow, fit bolts and tighten to 22 Nm (117 ft. lbs.).
16. Position alternator, fit mounting bolts and tighten to 45 Nm (34 ft. lbs.).
17. Position alternator cables and tighten terminal B+ to 18 Nm (113 ft. lbs.) and terminal D+ to 5 Nm (3.5 ft. lbs.).
18. Position auxiliary housing, fit bolts and tighten to 40 Nm (30 ft. lbs.). Fit nut and tighten to 22 Nm (17 ft. lbs.).
19. Clean jockey pulley mating faces.
20. Position jockey pulley and tighten bolt to 50 Nm (37 ft. lbs.).
21. Clean PAS pump pulley mating faces.
22. Position PAS pump pulley, fit bolts and tighten to 22 Nm (17 ft. lbs.).
23. Secure injector harness and connect injector multiplugs.
24. Connect multiplug to coolant thermistor.