Upper intake manifold
M43TU engine
Note. Installation will require a new manifold gasket and new pressure control valve o-rings.
1. Turn off the ignition.
2. To improve access, remove the inlet air duct of the ventilation and interior heating system in the rear of the engine compartment as follows.
- A) Remove the cabin air filter cover by turning its retainers 90°counterclockwise. Pull the filter out of the housing.
- b) Unfasten the latches and remove the wires from the box (see fig. 12.21).
- V) Remove the four screws and pull the cabin filter housing forward (see fig. 12.22).
3. Disconnect the accelerator cable from the throttle body as described in paragraph 5. Disconnect the cable in the same way "cruise control" (if there).
4. Release the clamps and remove the inlet air duct together with the air flow sensor. Disconnect the electrical plug from the flow meter and the vacuum hose from the air duct.
5. Turn out two bolts of fastening of an arm on the forward party of a collector and a bolt behind a collector (pic. 13.5, a, b). On the front bracket, release the wiring harness from the fasteners.
6. Disconnect the vacuum hose from the front of the manifold (pic. 13.6).
7. Disconnect the electrical connectors for the throttle position sensor and the idle air valve.
8. Loosen the clamp and disconnect the brake booster vacuum hose from the manifold.
9. Turn away nuts/bolts and remove the top section of a collector (pic. 13.9).
10. Installation is carried out in sequence. the reverse of the withdrawal, taking into account the following remarks.
- A) Replace upper manifold seals.
- b) Route the hoses and wires in the same way. as before disassembly.
- V) Connect and adjust the accelerator cable as indicated in paragraph 5.
Lower intake manifold
M43TU engine
11. Relieve the pressure in the fuel system (see paragraph B).
12. Remove the upper section of the manifold as described above.
13. Drain the coolant.
14. Remove the nozzles as described in paragraph 12.
15. Turn out a bolt of fastening of an arm of a tube of an oil probe to a collector.
16. Release from the bottom section of a collector a plait of wires of the engine.
17. Turn out bolts of fastening of a basic arm of a collector (pic. 13.17).
18. Disconnect from a collector and from gauges the remained wires and hoses. Mark them for correct installation.
19. Disconnect the coolant hose from the manifold flange (pic. 13.19).
20. Turn away nuts of fastening of the bottom section of a collector to a head of cylinders and remove a collector (pic. 13.20).
21. Installation is carried out in the reverse order, taking into account the following notes.
- A) When installing the lower section of the manifold, replace the seals.
- b) When installing the top section of the manifold, replace the seals (pic. 13.21).
- V) Route wires and hoses in the same way as they were laid before disassembly. Connect the connectors according to the labels. made during disassembly.
- G) Install nozzles (see paragraph 12).
- d) Install the upper section of the manifold as described earlier in this paragraph.
- e) Finally fill the fuel system (insert the fuel pump fuse and turn on the ignition). Check for leaks before starting the engine.
Intake connector
N42 engine
Note. Access to the underside of the collector is limited.
22. Turn off the ignition. Remove the air cleaner. as stated in paragraph 12.
23. Remove the fuel rail and injectors (see paragraph 12).
24. In the left corner of the engine compartment, turn the latches 90°and remove the dividing panel. Remove the hose and wires from the panel along with the sealing sleeves (see fig. 12.23).
25. Separate electric sockets on the throttle body and on a collector. Release all wires and cables from the fasteners on the manifold. Disconnect the tire from the dipstick guide tube.
26. On the underside of the manifold, loosen the clamp and disconnect the fuel tank ventilation hose from the manifold.
27. Under a collector turn out a bolt of fastening of a tube of an oil dipstick. then remove the two screws securing the support bracket to the manifold (fig 13.27). The propellers are easier to access from below, except on air-conditioned models where the front propeller can be accessed from above.
28. Under the starter, remove the bolt that secures the cooling system pipe bracket to the engine crankcase. This will allow the tubes to be pushed back, making it easier to remove the manifold.
29. Disconnect the ventilation hose from the upper side of the manifold (pic. 13.29).
30. Remove the two nuts securing the oil separator to the underside of the manifold (pic. 13.30).
31. Turn out five bolts of fastening of a collector and remove a collector from a head of cylinders (pic. 13.31).
32. Check the condition of the manifold seals and, if necessary, replace them with new ones.
33. Installation of the collector is carried out in reverse order, taking into account the following remarks.
- A) Correctly position the oil separator with the guides towards the manifold.
- b) Securely shade the manifold mounting bolts.
M52TU and M54 engines
34. To expand the working space, remove the inlet air duct of the heating and ventilation system from the rear side of the engine compartment as follows.
- A) Rotate 90°counterclockwise with a bashing the three retainers of the cabin air filter cover and remove the cover. Pull out the filter.
- b) Unfasten the four latches on the wiring duct and remove the wiring from the duct (see fig. 12.31).
- V) Remove the four screws securing the cabin filter housing and pull out the housing.
- G) Pull up the seal in the left corner of the engine compartment, turn the two latches counterclockwise and slide the separation panel slightly forward (see fig. 12.23).
- d) Remove the two screws and pull the air duct up (see fig. 12.24).
35. Remove the throttle body (paragraph 11) and fuel rail with injectors (paragraph 12).
36. Open the jump start terminal on the right side of the engine compartment and disconnect the bus to the starter (pic. 13.36).
37. On the left side of the front side of the cylinder head, disconnect the electrical connector of the VANOS camshaft adjuster solenoid.
38 Disconnect the crankcase ventilation hose from the cylinder head cover.
39. Press inwards the latch and disconnect the hose from the fuel tank vent valve (pic. 13.39)
40. Release the wires from the mounts to the manifold and support bracket.
41. Disconnect the vacuum brake booster hose. To do this, cut the clamp and pull the plastic tube out of the hose.
42. Turn away nine nuts of fastening of a collector to a head of cylinders, and also a nut of a basic bracket under a collector (pic. 13.42, a, b) Remove the manifold from the engine. On the M54 engine, disconnect the fuel pressure regulator vacuum hose. Remove seals.
43. Check the condition of the seals and, if necessary, replace with new ones.
44. The collector is installed in the reverse order of removal.
An exhaust manifold
M43TU engine
Note. To install, you need new manifold nuts and a new gasket.
45. To improve access, raise the front of the car and place it on secure supports. Remove the crankcase protection from under the engine.
46. From under the car, unscrew the nuts securing the exhaust pipe to the exhaust manifold (pic. 13.46).
47. Remove the bolts connecting the two halves of the exhaust system support on the gearbox bracket (see figure 14.4).
48. Release the bolt securing the support halves to the bracket, then remove the exhaust pipe from the exhaust manifold studs. Remove the gasket.
49. In the engine compartment, unscrew the manifold mounting nuts. Loosen the nuts securing the secondary air injection tube to the manifold (if there) and pick up the handset.
50. Remove the manifold from the studs and remove from the engine compartment. Remove the manifold gasket.
51. It is possible that when loosening the manifold nuts, some studs will come out. These studs must be screwed into place in the cylinder head before the manifold is installed. To do this, screw two nuts onto the stud, pull them together, and screw the stud by the top nut.
52. Installation of the collector is carried out in reverse order. When installing, replace the gasket and nuts.
N42 engine
53. Raise the front of the car and place it on secure supports. Remove the crankcase protection from under the engine.
54. Turn out eight bolts and remove the forward amplifier between the lower suspension arms. When installing the amplifier mounting bolts will need to be replaced.
55. Trace sensor wiring (ov) oxygen and disconnect it (their) electrical connector. If there are two sensors, then mark the connectors so as not to confuse them during installation.
56. Turn away bolts and nuts and disconnect a reception pipe from a collector.
57. Turn out nuts of fastening of a final collector with the screen and remove them from a head of cylinders (pic. 13.57). The pad can be thrown away. It is possible that when loosening the manifold nuts, some studs will come out. These studs must be screwed into place in the cylinder head before the manifold is installed. To do this, screw two nuts onto the stud, pull them together, and screw the stud by the top nut.
58. Installation of the collector is carried out in reverse order. When installing, replace the gasket and nuts.
M52TU and M54 engines
59. To expand the working space, remove the inlet air duct of the heating and ventilation system from the rear side of the engine compartment as follows.
- A) Rotate 90°counterclockwise the three retainers of the cabin air filter cover and remove the cover. Pull out the filter.
- b) Unfasten the four latches on the wiring duct and remove the wiring from the duct (see fig. 12.21).
- V) Remove the four screws securing the cabin filter housing and pull out the housing.
- G) Pull up the seal in the left corner of the engine compartment, turn the two latches counterclockwise and slide the separation panel slightly forward (see fig. 12.23).
- d) Remove the two screws and pull the air duct up (see fig. 12.24).
60. Raise the front of the car and place it on secure supports. Remove the crankcase protection from under the engine.
61. Turn out eight bolts and remove the forward amplifier between the lower suspension arms. When installing the amplifier mounting bolts will need to be replaced.
62. Hook the hoist straps to the engine rigging eye and pull the engine up to take the weight off the engine mounts.
63. From under the car, remove the right engine mount with the support arm.
64. Remove the plastic cover over the injectors. To do this, remove the two plugs and unscrew the screws under them.
65. Trace sensor wiring (ov) oxygen and disconnect it (their) electrical connector. If there are two sensors then mark the connectors so as not to mix them up during installation.
66. Turn away bolts and nuts and disconnect a reception pipe from a collector.
67. Raise the engine about 5 mm.
68. Loosen the nuts securing the front manifold and remove it from the engine (pic. 13.68). Be careful not to damage the manifold oxygen sensor.
69. Remove the rear manifold in the same way. Again, be careful not to damage the oxygen sensor
70. Installation of collectors is carried out in the reverse order, taking into account the following remarks.
- A) Lubricate the manifold studs with graphite grease (or other compound that prevents the threaded connection from seizing)
- b) Replace the pads under the manifold and under the downpipe.
- V) Tighten the connector nuts to the required torque.