Table of contents: Removal 🠇 Refitting 🠇
Removal
1. Disconnect the battery negative terminal (refer to "Disconnecting the battery").
2. Carry out the operations listed in paragraphs 2 to 5 of Section 12. Proceed as described under the relevant sub-heading.
1294 cc models
3. Release the retaining clips (where fitted) and disconnect all the relevant vacuum and breather hoses from the manifold. Make identification marks on the hoses to ensure that they are connected correctly on refitting.
4. Bearing in mind the information given in Section 7, slacken the retaining clips and disconnect the fuel feed and return hoses from the fuel rail. Where the original crimped-type Peugeot hose clips are still fitted, cut them off and discard; replace them with standard worm-drive hose clips on refitting.
5. Depress the retaining tangs and disconnect the wiring connectors from the four injectors. Free the wiring from any relevant retaining clips and position it clear of the manifold.
6. Undo the retaining bolts and remove the support brackets from the right- and left-hand ends of the manifold.
7. Undo the manifold retaining nuts and withdraw the manifold from the engine compartment. Recover the manifold gaskets and discard them; new ones must be used on refitting.
1124, 1360 and 1587 cc (8-valve) models
8. Where fitted, depress the retaining clip and disconnect the wiring connector from the idle speed auxiliary air valve, which is mounted on the underside of the manifold. Slacken the retaining clip and disconnect the vacuum hose connecting the valve to the inlet duct, leaving the valve free to be removed with the manifold.
9. Release the retaining clips (where fitted) and disconnect all the relevant vacuum and breather hoses from the manifold. Make identification marks on the hoses, to ensure that they are connected correctly on refitting.
10. Bearing in mind the information given in Section 7, slacken the retaining clips and disconnect the fuel feed and return hoses from the fuel rail. Where the original crimpedtype Peugeot hose clips are still fitted, cut them off and discard; replace them with standard worm-drive hose clips on refitting.
11. Depress the retaining tangs and disconnect the wiring connectors from the four injectors. Free the wiring from any relevant retaining clips and position it clear of the manifold.
12. Where necessary, undo the retaining bolts and remove the support bracket from the underside of the manifold.
13. Undo the manifold retaining nuts and withdraw the manifold from the engine compartment. Recover the four manifold seals and discard them; new ones must be used on refitting.
1587 cc (16-valve) models
14. Chock the rear wheels then jack up the front of the vehicle and support it on axle stands (see "Jacking and vehicle support").
15. Working under the vehicle and using a socket and long extension bar, undo the two rear bolts securing the inlet manifold upper part to the lower part.
16. From above, undo the centre bolt and the two remaining bolts, one each side, then lift off the upper part of the inlet manifold, complete with throttle housing.
17. Bearing in mind the information given in Section 7, slacken the retaining clips and disconnect the fuel feed and return hoses from the fuel rail. Where the original crimpedtype hose clips are still fitted, cut them off and discard; replace them with standard wormdrive hose clips on refitting.
18. Depress the retaining tangs and disconnect the wiring connectors from the four injectors. Free the wiring from any relevant retaining clips and position it clear of the manifold.
19. Slacken and remove the fuel rail retaining bolts/nuts, then carefully ease the fuel rail and injector assembly out from the inlet manifold and remove it from the vehicle. Remove the O-rings from the end of each injector and discard them; they must be renewed whenever they are disturbed.
20. Release the retaining clamps and free the fuel supply pipes from the rear of the manifold lower part.
21. Undo the retaining nuts securing the manifold lower part to the cylinder head and withdraw the manifold from the engine compartment. Recover the gasket or manifold seals according to fitment and discard them; new ones must be used on refitting.
Refitting
22. Refitting is a reverse of the relevant removal procedure, noting the following points:
- a) Ensure that the manifold and cylinder head mating surfaces are clean and dry.
- b) On 1294 cc models, fit the new gaskets onto the studs, then refit the manifold and tighten its retaining nuts to the specified torque.
- c) On 1360 and 1587 cc models, locate the new seals in their recesses in the manifold. Refit the manifold and tighten its retaining nuts to the specified torque.
- d) On 1587 cc (16-valve) models, fit new O-rings to all injector unions disturbed on removal. Apply a smear of engine oil to the O-rings to aid installation, then ease the injectors and fuel rail into position, ensuring that none of the O-rings are displaced.
- e) Ensure that all relevant hoses are reconnected to their original positions and are securely held (where necessary) by the retaining clips.