Removing
Place the car in the workplace, brake with the parking brake, turn off the ignition and disconnect the wire terminal "masses" from the battery.
For vehicles with K4M engine
Remove intake silencer (see here), air filter housing and throttle body (see here).
Disconnect the throttle cable 1, Figure 11-8, from the intake manifold 5.
Figure 11-8 - Removing the intake manifold of the K4M engine: 1 - throttle cable; 2 - block of the wiring harness to the ignition coils; 3 - block of the wiring harness to the air temperature sensor; 4 - block of the wiring harness to the incoming air pressure sensor; 5 - intake manifold
Detach blocks 2 from ignition coils.
Disconnect connector 3 from air temperature sensor.
Disconnect connector 4 from the intake air pressure sensor.
Loosen bolts 1...7, Figure 11-9, and remove the intake manifold assembly with air temperature sensor and intake air pressure sensor (interchangeable head 8, extension, crank).
Figure 11-9 - Removing the intake manifold of the K4M engine: 1... 7 - intake manifold mounting bolts
For vehicles with K7M engine
Remove air filter housing (see here).
Disconnect:
- ball ends 1, figure 11-10 throttle actuator (flat screwdriver);
- block 2 of the wiring harness from the temperature sensor;
- block 3 of the wiring harness from the pressure sensor;
- brake booster vacuum hose from the intake manifold;
- tube 4 crankcase ventilation from the intake manifold;
- crankcase ventilation hose from the intake manifold.
Remove throttle body 5 (see here).
Figure 11-10 - Removing the intake manifold of the K7M engine: 1 - ball tips of the throttle actuator; 2 - block of the wiring harness to the air temperature sensor; 3 - block of the wiring harness to the pressure sensor; 4 - crankcase ventilation tube; 5 - throttle pipe; 6 - fuel rail; 7 - supply pipeline of the fuel rail; 8 - intake manifold mounting bolt
Press the connector's spring clip and disconnect the supply line 7 from the fuel rail 6.
Unscrew nut 1, Figure 11-11, studs securing intake manifold 2 to bracket 3 (interchangeable head 13, extension, crank).
Figure 11-11 - Disconnecting the intake manifold of the K7M engine from the bracket: 1 - intake manifold stud nut; 2 - intake manifold; 3 - bracket
Disconnect the intake manifold wiring harness.
Unscrew the four upper bolts 8, Figure 11-10, fastening the intake manifold (interchangeable head 10, extension, ratchet wrench).
Loosen the three lower intake manifold nuts (interchangeable head 10, extension, ratchet wrench).
Remove intake manifold.
Installation
Warning: Pretty simple in appearance, but an extremely important element of the power system is the intake manifold gasket. It seems that the requirements for it are not particularly complicated, and the materials used are ordinary - simple elastic cardboard, however, in the event of a violation of the integrity of the gasket, the power system of a modern car will go into emergency mode. On older and simpler injection systems, damage to the injection leads to loss of power and erratic engine operation.
For vehicles with K4M engine
Attention. All gaskets must be replaced.
Before installing the intake manifold, install a new gasket on the intake manifold.
Install the intake manifold to the vehicle.
Install and tighten the mounting bolts in the order shown in Figure 11-9. Bolt tightening torque 9 Nm (0.9 kgf·m) (interchangeable head 8, extension, knob, torque wrench).
Connect connector 4, Figure 11-8, to the intake air pressure sensor.
Connect connector 3 to the air temperature sensor.
Attach blocks 2 to the ignition coils.
Connect throttle cable 1 to intake manifold 5.
Install the throttle body, air filter housing and intake silencer (see above).
For vehicles with K7M engine
Attention. All gaskets must be replaced.
Install the intake manifold and tighten the lower center mounting nut (interchangeable head 10, extension, ratchet wrench).
Install intake manifold bolts and nuts (interchangeable head 10, 13, extension, ratchet wrench).
Tightening torques:
- intake manifold bolts 25 Nm (2.5 kgf·m);
- intake manifold nuts 25 Nm (2.5 kgf·m).
Further installation is carried out in the reverse order of removal.
Operations for all vehicle configurations
Attach wire terminal "masses" to the battery.