1 - PCV valve; 2 - Vacuum brake booster; 3 - Power valve actuator; 4 - Inlet air duct; 5 - EGR valve with a socket; 6 - Assembling the IAC valve / shutting off the air supply; 7 - TPS / throttle closed position switch; 8 - Ignition distributor cover with BB wires
Attention! Proceed with the procedure only after the final cooling of the power unit.
Upper section of the inlet pipeline (injection chamber)
1. Relieve the pressure in the supply system (see chapter Power and exhaust systems), then disconnect the negative cable from the battery.
Attention! If the stereo system installed in the car is equipped with a security code, before disconnecting the battery, make sure that you have the correct combination to activate the audio system!
2. Drain the coolant from the radiator and engine block, empty the cooling system, (see chapter Settings and ongoing maintenance).
3. Remove the intake duct (see chapter Power and exhaust systems), then disconnect the linkage, hoses and electrical wiring from the throttle body.
4. Disconnect the BB wires from the spark plugs and release them from the intermediate clamps on the injection chamber housing. Remove the distributor cap and move it aside without disconnecting the BB wires.
5. Acting in the reverse order shown in the illustration, loosen the bolts securing the upper section of the inlet pipeline. Remove the upper pressure chamber with the throttle body connected to it. Disconnect the ground bus connected to the bottom of the pressure chamber. Moving from the center to the edges, unscrew the fixing bolts of the bottom of the camera.
6. Before installing the top section, carefully clean the mating surfaces of the pipeline, the upper and lower parts of the injection chamber. After completely removing traces of the old gasket and sealant from the surfaces, wipe them with a rag soaked in solvent.
7. Put a new gasket on the inlet pipe studs, then seat the lower part of the discharge chamber on top and, moving from the edges to the center, tighten the fixing bolts with the required force.
8. Place the gasket on the bottom chamber and install the top of the chamber. In a strictly defined order, tighten the upper chamber mounting bolts with the required force.
Lower section of the inlet pipeline
1. Remove the top section of tubing.
2. Disconnect the wiring from the coolant temperature switch, CTS, power valve control solenoid valve, EGR solenoid valve, and EGR temperature sensor.
3. Mark and disconnect all vacuum hoses interfering with the dismantling of the lower section of the pipeline.
4. Remove the fuel line with injection injectors from the pipeline (see chapter Power and exhaust systems).
5. Turn out fixing bolts and disconnect from the end face of the pipeline of a tube of a cooling path turned to transmission.
6. Acting in the reverse order of that shown in the illustration, in several steps (1/4 turn per approach) loosen the bolts/nuts securing the pipeline.
7. If pipeline "stuck" and does not lend itself to separation from the cylinder heads, tap it with a hammer through a block of wood.
Attention! Never pry the pipeline with a lever under the mating surface.
8. Thoroughly clean the mating surfaces of the pipeline and cylinder heads, completely removing traces of the old gasket material and sealant from them and then wiping them with a cloth soaked in acetone.
9. Before proceeding with the installation of new gaskets and pipeline, check the condition of the tubes of the cooling path laid under it. Install the gaskets and piping, - make sure that the components are correctly positioned on the guide pins. Screw on the fixing nuts.
10. In a strictly defined order, tighten the pipeline fasteners to the required torque in three stages.
Note. Nut tightening torques are different from bolt tightening torques.
11. Further installation is carried out in the reverse order to the dismantling of the components. Don't forget to fill the cooling system and change the engine oil (see chapter Settings and ongoing maintenance).
12. Start the engine and check for signs of fuel, coolant, and vacuum losses.