4A•18 Fuel and exhaust systems
20.16 Disconnecting the brake servo
vacuum hose from the inlet manifold
7 Check the upper mounting bracket
grommets, and renew them if necessary.
8 Lower the intercooler onto its mountings.
9 Move the intercooler forwards against the
condenser, then locate the upper mounting
bracket and grommets on the studs on the
intercooler and condenser. The radiator
mounting end must be facing to the rear.
10 Refit the bolts securing the intercooler to
the air conditioning condenser, and tighten to
the specified torque.
11 Reconnect the hose to each end of the
intercooler, and tighten the clips.
12 Where applicable, refit the plastic guard
under the intercooler.
13 Refit the radiator with reference to Chap-
LH-Jetronic fuel injection models
1 Disconnect the battery negative lead.
2 Loosen the clip and disconnect the air
supply hose from the inlet manifold.
3 Refer to Section 15 or 16 (as applicable) and
remove the throttle housing from the inlet
manifold. If preferred, the hoses and
accelerator cable may remain attached, and
the housing positioned to one side.
20.22 Removing the right-hand stay
(arrowed) from the lower inlet manifold
4 Remove the fuel supply rail from the inlet
manifold as described in Section 15 or 16 (as
5 On models with automatic transmission,
disconnect the kickdown cable from the
bracket on the inlet manifold.
6 Release the turbo oil supply pipe from the
clip on the inlet manifold.
7 Disconnect the brake servo vacuum hose
from the inlet manifold.
8 Unscrew the mounting bolts securing the
inlet manifold to the cylinder head. Also
unscrew the lower bolt from the steady bar.
9 Withdraw the inlet manifold from the
cylinder head. Recover the gasket.
10 Refitting is a reversal of removal, but fit a
new gasket and tighten the mounting bolts to
the specified torque.
Trionic engine management
11 Disconnect the battery negative lead.
Upper inlet manifold
12 To remove the upper section of the inlet
manifold, first disconnect the plastic duct
between the throttle housing and the inlet
13 Disconnect the idle air control valve hose
from the throttle housing.
14 Disconnect the cruise control cable.
15 Unscrew the mounting nuts, and remove
2O.23a Coolant temperature sensor wiring
the throttle housing from the inlet manifold.
Position the housing to one side.
16 Loosen the clip and disconnect the
vacuum hoses for the fuel pressure regulator
and the brake servo (see illustration). Also
disconnect the small crankcase breather
17 Disconnect the EVAP hose from the inlet
manifold, and also disconnect the hose
leading to the pressure sensor.
18 Unscrew and remove the upper retaining
screws from the bracket on the side of the
upper inlet manifold, and loosen the lower
19 Unbolt and remove the oil filler pipe
20 Unscrew the remaining screws securing
the upper inlet manifold to the lower manifold,
and remove the upper manifold. Also
disconnect the idle air control valve wiring.
21 Check the rubber hoses between the
upper and lower inlet manifolds, and renew if
Lower inlet manifold
22 Unscrew the bolts securing the two stays
to the inlet manifold (see illustration). Where
necessary, also loosen the stay bottom
23 Disconnect the plug from the coolant
temperature sensor. Also remove the screws
securing the earth wires and wiring support to
the inlet manifold (see illustrations).
24 Disconnect the fuel supply and return
hoses from the fuel rail and pressure regulator.
2O.23b Earth wire screws (arrowed) on the
lower inlet manifold
20.23c Detaching the earth wire at the
timing chain end of the engine
20.23d Removing the wiring support from
the inlet manifold