Contents: Removal ⬇ Installation ⬇
Removal
Note: The charge air intercooler is integrated into the intake manifold, they are one piece.
1. Loosen the mounting clamps and remove the front upper cooling system hose (for more details, see the corresponding section in the chapter "Cooling system").
2. Remove the high-pressure fuel lines (for more details, see the corresponding section in the chapter "Engine power supply and control system").
3. Remove the air filter housing (for more details, see the relevant section in this chapter).
4. Unscrew the mounting screws (arrows) shown in the figure below.
5. Release the fastening clamp (2) shown in the figure below. Then disconnect and remove the air duct pipe (1), as shown in the figure below.
6. Disconnect the wiring harness connector (4) shown in the figure below.
7. Loosen the mounting clamps (1), (2) and disconnect the fuel pipes shown in the figure below.
8. Unscrew the fastening screw (3), then move the fuel pipes towards the rear of the body, as shown in the figure below.
9. Unlock the lock (arrow), disconnect the vacuum hose (1) shown in the figure below.
10. Unscrew the fastening screw (3), then disconnect the vacuum hose (2), as shown in the figure below.
For engines with factory designation CRKB
11. Remove the cooling fan cover.
12. Disconnect the wiring harness connector (1) shown in the figure below.
13. Loosen the fastening clamp (2) shown in the figure below.
Continuation for all modifications
14. Disconnect the wiring harness connectors shown in the figure below.
- post-intercooler charge air temperature sensor wiring harness connector (1);
- blower air pressure sensor wiring harness connector (3);
- intake air temperature sensor wiring harness connector (4);
- throttle body module wiring harness connector (5).
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15. Loosen the mounting clamps (2) and (7), then disconnect the water hose (6), shown in the figure below.
16. Unscrew the fastening screw (1) of the oil dipstick guide tube, as shown in the figure below.
17. Loosen the mounting nuts (5) and remove the mounting bracket (6) from the double mounting screw (4), as shown in the figure below.
18. Unscrew the fastening screws (4) and (7) shown in the figure below.
19. Unscrew the mounting screws (2) and (3) of the intake manifold stand, as shown in the figure below.
20. Unscrew the mounting bolts (from 10th to 1st) intake manifold using a special head XZN 10 (T10501). Remove the intake manifold assembly as shown in the figure below.
Installation
1. Install a new intake manifold gasket onto the cylinder head guide pins.
Caution: Use extreme caution when installing the gasket onto the guide pins.
2. Tighten the mounting bolts (1-10) in the specified sequence to the required tightening torque.
3. Next, installation is carried out in the reverse order of removal.
Note: Always replace the gaskets after disassembly.
4. Install the air filter housing assembly (for more details, see the relevant section in this chapter).
5. Install the high-pressure fuel lines (for more details, see the relevant section in the chapter "Engine power supply and control system").
6. Install the front upper cooling system hose (for more details, see the corresponding section in the chapter "Cooling system").