Note. Replace gasket (-And) manifold during installation.
Intake manifold
Removing
1. Disconnect the ground wire from the battery (see «Disconnecting the battery»).
2. Remove the intake air line and, on 1.9L engines, the air distribution housing as described in paragraph 3.
3. Turn away six nuts of fastening of flanges of a collector to a head of cylinders and turn out one bolt with a hex head from the central flange. Remove washers from manifold studs (in the presence of).
4. Remove a collector from a head of cylinders. Remove the pads.
Installation
5. Installation is carried out in the reverse order of removal, taking into account the following points.
- A) Replace gasket (-And) when installing the manifold.
- b) Install the air distribution housing and/or air intake duct as described in paragraph 3.
An exhaust manifold
Removing
6. Remove the intake manifold as described above.
7. Disconnect the exhaust pipe from the manifold (see paragraph 16).
8. On some models, it may be necessary to remove the bolts and remove the resonator chamber from the manifold to provide enough space to remove the manifold.
9. On DJY models (XUD9Y engine) remove the EGR valve (EGR) from the exhaust manifold as described in chapter 4D.
10. Turn away six nuts of fastening of a final collector and remove remote elements from hairpins.
11. Remove the exhaust manifold from the cylinder head and remove the gaskets.
12. It may happen that some of the manifold mounting studs will be unscrewed from the cylinder head when unscrewing the manifold mounting nuts. In this case, immediately after removing the manifold, the studs should be screwed into the cylinder head using two nuts tightened relative to each other.
Installation
13. Installation is carried out in the reverse order of removal, taking into account the following points:
- A) Replace manifold gaskets.
- b) Connect the downpipe of the exhaust system to the exhaust manifold as described in paragraph 16.
- V) If applicable, install the EGR valve as described in chapter 4D.
- G) Properly connect and route all relevant hoses and fuel lines.