REMOVAL & INSTALLATION
B20E, B20F and B30F Engines
- On B30F engines, remove the air cleaner. On B20E and B20F engines, remove the inlet duct-to-air cleaner hose at the inlet duct.
- Disconnect the battery, negative cable first.
- Disconnect the throttle and downshift linkage. Remove and label the hoses from the manifold to the PCV valve, distributor advance, and power brake booster.
- Disconnect the contact for the throttle valve switch, and remove the ground cable for the inlet duct. On CI engines, remove the fuel injectors.
- Remove the bolts for the inlet duct stay. Remove the inlet duct-to-cylinder head retaining nuts and slide the inlet duct off the studs.
- Discard the old gasket. To install, reverse the above procedure. Use a new inlet duct gasket.
See Figures 1, 2, 3 and 4
- Disconnect the pipe between the EGR valve and the manifold.
- Disconnect and remove the cold start injector and remove the crankcase ventilation hose.
It is not necessary to physically remove the cold start injector from the manifold if its fuel line and electrical connector are removed.
- Remove the rubber pipes and electrical connection and remove the auxiliary air valve.
- Remove the brace between the engine block and intake manifold. On B21FT engines, disconnect the turbocharger inlet hose (between the turbo unit and the intake manifold) and plug the hose with a clean rag.
- Label and disconnect the distributor vacuum hose at the intake manifold.
- Loosen the clamp and slide off the large rubber hose at the bottom of the intake manifold.
- Remove the eight 13mm nuts and remove the intake manifold and gasket. Reinstall with new gaskets. Remember to remove the plug from the turbo inlet hose if so equipped. Installation is the reverse of removal. Tighten the manifold-to-cylinder head nuts to 15 ft. lbs. (20 Nm). Double check all hose and wiring connections for proper placement and routing.
- Remove the air mass meter and the air intake hose.
- Detach the throttle pulley from the intake manifold and remove the link rod from the throttle lever.
- Separate the throttle housing from the intake manifold and cut the cable tie holding the wiring to the vacuum hose connections.
- Disconnect the lines and hoses from the manifold, including the brake booster vacuum hose, the evaporation line, the oil trap, the fuel pressure regulator line and the air control valve line. If the car is equipped with a vacuum tank, disconnect its line at the manifold.
- Disconnect the fuel return line at the distribution pipe. Disconnect the wiring to the injectors and remove the distribution pipe and injectors. Immediately protect these components from the entry of any dirt.
- Unbolt and remove the intake manifold from the engine.
- If installing a new manifold, it is necessary to transfer the various hose nipples and plugs to the new part. Install the manifold with a new gasket. Starting with the center bolts and working outward, tighten the bolts to 15 ft. lbs. (20 Nm).
- Reconnect the hoses to their proper ports.
- Position the injector wiring between cylinders 2 and 3 and reinstall the fuel distributor rail and the injectors. Tighten the pipe and the ground wires to the block. Connect the fuel pressure regulator line to the intake manifold.
- Install the throttle pulley and connect the link rod.
- Install the throttle housing with a new gasket. Check the operation of the throttle stops and switches.
- Install the air mass meter and air inlet hose.
See Figures 5, 6 and 7
Instructions below are for the B280 family of engines. B27 and B28 are similar, but older engines may not contain all components noted below. All wires and hoses should be labled at the time of removal. The amount of time saved during reassembly makes the extra effort well worthwhile.
- Disconnect the negative battery cable.
- Loosen the gas cap to allow pressure within tank to equalize, then retighten the cap.
- Remove the air intake duct. Remove the oil filler cap and hoses.
- Disconnect the fuel lines from the filter and the fuel return pipe.
- Remove the air control valve from the inlet manifold.
- Remove the spark plug wires from the spark plugs, the ignition coil and the wire holder; position the wires out of the way.
- Remove the injectors from the cylinder head. Plug the injector holes with paper or a rag.
- Loosen clips and remove distributor cap. This prevents damage to the cap when removing the manifold.
- Label and remove the vacuum hoses from the charcoal canister and the power brake booster. Also disconnect the vacuum hose at the right rear corner of the manifold and the hose to the T-connector. For ease of reinstallation, disconnect all of these hoses only at the manifold end.
- Loosen the retaining bolts and remove the front (double horseshoe) section of the intake manifold. Plug the large holes in the manifold with crumpled paper.
- Remove cables from the throttle control pulley. There will always be a throttle cable; there may be a kickdown cable (automatic transmission) and possibly a cruise control cable.
- Label, disconnect, and move to one side the wiring harness(es).
- Using a 5mm Allen wrench, loosen and remove the control pressure regulator. Lay the regulator on top of the engine.
- Remove the four bolts holding the intake manifold. Remove the manifold carefully. Plug the intake ports in the engine immediately.
- Remove the plugs from the intake ports on the engine. Using NEW O-rings (seals), install the manifold in place, install the four bolts and tighten to 7-11 ft. lbs. (9-15 Nm). Do not overtighten these bolts
- Reattach the distributor cap.
- Install the injectors.
- Connect and fasten the spark plug wires.
- Replace the control pressure regulator and air control valve.
- Connect and fasten wiring harness(es).
- Connect cables to the throttle pulley.
- Using NEW gaskets and O-rings, install the front section of the manifold. Do not over tighten bolts. Don't forget to remove the plugs in the ends of the manifold.
- Connect all vacuum hoses. Refer to illustration for help.
- Reconnect the lines to the fuel filter and the fuel return. Reconnect the air intake tube and replace the oil filler cap and hoses.
- Connect the battery cable. Start the engine and check your work. It may be necessary to adjust the throttle cable and/or idle speed.
- Remove the air cleaner to intake manifold bellows.
- Remove the preheat hose and panels. Remove the hose and wire from the safety valve, located on the front end of the manifold. Remove the hose to the fuel limiter; this hose is located on the rear of the manifold.
- On the D24T engine, disconnect the turbocharger inlet hose (between the turbo unit and the intake manifold) and plug the hole immediately. The hose can be pushed up into the manifold.
- Using a 6mm Allen wrench, remove the ten attaching bolts and remove the intake manifold.
- Installation is the reverse of removal. When installing gasket, make sure the green side faces the cylinder head and apply a light coat of lubricant to keep the gasket in place during installation. Check the O-rings for the safety valve and compressor (turbo) tube and replace the rings if needed. Tighten the manifold bolts to 18 ft. lbs. (24 Nm).
When installing the bellows to the intake manifold, make sure the PCV hose is positioned so that it will not make contact with the hood when the hood is closed.