Table of contents: 1.9 liter engines 🠇 2.1 liter engines 🠇
1.9 liter engines
Caution! The intake and exhaust manifolds are mounted on the same gasket. Therefore, it is recommended to remove both manifolds at the same time so that the gasket can be replaced.
Removal
1. Disconnect the negative battery terminal.
2. Remove the air intake duct system from the top of the engine, attached to the intake manifold.
3. Remove the vacuum hose, then remove the two bolts securing the control diaphragm to the manifold. Move the diaphragm assembly to the side.
4. Raise the front of the car and secure it on stands. Remove the mudguard from under the engine.
5. If the intake manifold has not been removed, disconnect the inlet from the turbocharger outlet. Cover the turbocharger opening with a clean rag.
6. Remove the two bolts securing the EGR valve to the top of the exhaust manifold.
7. Remove the intake manifold mounting bolts. Loosen, but do not completely remove, the central manifold mounting bolt, which is located in the manifold groove.
8. Remove the manifold from the cylinder head.
Installation
1. Installation is carried out in the reverse order of removal.
2. The following points should be taken into account:
- replace the gaskets;
- tighten all bolts to the specified torque;
- replace the gasket when installing the EGR valve;
- check that all hoses and pipes are properly installed and securely fastened.
2.1 liter engines
Removal the top part
Caution: There is not enough space between the exhaust manifold and the engine compartment bulkhead to remove the lower portion of the manifold on a vehicle-mounted engine.
1. Loosen the clamp (indicated by the arrow) and remove the pipe from the top of the manifold.
2. Remove the screw clamp securing the flexible portion of the EGR pipe to the manifold.
3. Unscrew the four bolts (indicated by arrows) fastenings.
4. Lift the top of the manifold.
5. Remove the four seals that connect the pipes from the bottom of the manifold.
Installation
1. Installation is carried out in the reverse order of removal.
2. Replace the four rubber seals that connect the pipes.
3. Tighten all bolts to the specified torque.
4. Secure the EGR pipe with a new screw clamp (indicated by the arrow).
Removal the bottom part
1. Remove the power unit (engine with gearbox).
2. Remove the top of the manifold.
3. Unscrew the mounting bolts (indicated by arrows) manifold, noting the position of the pipe support hanger on the right side of the manifold.
4. Remove the manifold from the cylinder head by unscrewing the EGR pipe.
5. Remove the manifold gasket.
Installation
1. Installation is carried out in the reverse order of removal.
2. Please consider the following points:
- replace manifold gasket;
- tighten the bolts to the required torque;
- install the top part of the manifold;
- install the power unit.