1.9 liter engines
Attention! 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.
Removing
1. Disconnect the negative battery terminal.
2. Remove the air intake pipe system from the top of the engine attached to the intake manifold.
3. Remove the vacuum hose, then unscrew 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 piping has not been removed, disconnect the inlet from the turbocharger outlet. Cover the turbocharger opening with a clean cloth.
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 unscrew, the central manifold mounting bolt, which is located in the groove of the manifold.
8. Remove the manifold from the cylinder head.
Installation
1. Installation is made in sequence, return to removal.
2. The following points should be taken into account:
- replace gaskets;
- tighten all bolts to the required torque;
- replace the gasket when installing the EGR valve in place;
- check that all hoses and pipes are correctly installed and securely fastened.
2.1 liter engines
Removing the top
Attention! There is not enough space between the exhaust manifold and the bulkhead to remove the bottom of the manifold on a vehicle-mounted engine.
1. Loosen clamp (indicated by an arrow) and remove the pipe from the top of the manifold.
2. Remove the screw clamp that secures the flexible part of the EGR pipe to the manifold.
3. Unscrew the four bolts (indicated by arrows) mounts.
4. Raise the top of the manifold.
5. Remove the four seals connecting the pipes from the bottom of the manifold.
Installation
1. Installation is made in sequence, return to removal.
2. Replace the four rubber seals connecting the pipes.
3. Screw in all bolts the demanded moment.
4. Secure the EGR pipe with a new screw clamp (indicated by an arrow).
Removing the bottom
1. Remove the power unit (engine with gearbox).
2. Remove the top of the manifold.
3. Unscrew the fastening bolts (indicated by arrows) manifold, marking 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 made in sequence, return to removal.
2. Consider the following points:
- replace the manifold gasket;
- tighten the bolts to the required torque;
- install the upper part of the collector;
- install the power unit.