Models with 1.9L engine
Removing
1. Disconnect the ground wire from the battery (see «Disconnecting the battery»).
2. Release the fasteners on the right side and top plane of the engine cover, and then carefully, so as not to lose the rubber feet, remove the cover (pic. 3.1, a-c).
3. Release a collar and disconnect an inlet air line from the EGR valve. Release the clamp and disconnect the EGR pipe from the side of the EGR valve.
Note. If the piping is secured in place with a crimp-type clamp, discard the clamp and purchase a new one to use for installation.
4. Disconnect the vent hose from the left end on the top section of the manifold.
5. Turn out bolts of fastening of the top section of a collector to a head of cylinders and the lower section.
6. Remove the upper manifold section along with the EGR valve and disconnect the electrical connector and disconnect the vacuum hose from the EGR solenoid valve. Remove the four seals installed between the top and bottom sections.
7. For removal of the lower section of a collector turn out bolts of fastening of the pipeline EGR to the top section of a final collector and a cover of a head of cylinders. Disconnect the pipeline from the manifold and remove the gasket. Throw away the gasket; when installing, use a new one.
8. Turn away nuts and turn out a bolt of fastening of an inlet collector to a head of cylinders. Remove the EGR manifold assembly. Remove the manifold gaskets and discard them; when installing, use new ones.
Installation
9. Inspect all manifold studs for signs of damage and corrosion. Completely remove all traces of corrosion and repair or replace damaged studs.
10. Clean the mating surfaces and make sure they are not deformed. Install new manifold gaskets.
11. Route the EGR line through the lower section of the manifold and install both items as a single assembly. Tighten the manifold nuts and bolt to the specified torque.
12. Install a new gasket on the exhaust manifold, and then connect the EGR pipe and securely tighten the appropriate bolts.
13. Install a new seal at each of the joints in the top section of the manifold, and then install the top section of the manifold. while docking the electrical connector and connecting the vacuum hose to the EGR solenoid valve. Screw in the bolts, tighten them to the prescribed torque and connect the ventilation hose.
14. Connect the intake air line and the EGR line to the top section of the manifold and secure them with the appropriate clamps.
15. Verify that all rubber mounts are properly installed, and then install the engine cover and secure with retainers. Connect ground wire to battery.
Models with 2.0L engine
Removing
16. Remove the exhaust manifold as described in paragraph 18.
17. Turn away nuts and turn out bolts of fastening of an inlet collector to a head of cylinders (pic. 17.17). Remove the manifold and then the manifold gasket. Throw away the gasket; when installing, use a new one.
Pic. 17.17. nuts (A) and bolts (IN) intake manifold mounts (models with 2.0 l engine)
Installation
18. Inspect all manifold studs for signs of damage and corrosion. Completely remove all traces of corrosion and repair or replace damaged studs.
19. Clean mating surfaces and make sure they are not deformed. Install a new manifold gasket.
20. Install the manifold and tighten the appropriate nuts and bolts to the specified torque.
21. Install the exhaust manifold as described in paragraph 18.