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Gasket, intake manifold with secondary air injection pump (SAI)

Gasket, intake manifold with secondary air injection pump (SAI)

To remove


1. Remove Control module, Trionic T8 (589)

2. Remove Throttle body actuator unit (604)

3. Remove the battery cover.

4. Disconnect the negative cable from the battery.

5. Raise the car.

6. Remove the screw (A) for the SAI pipe's bracket.


7. Remove the lower screws (B) for the SAI pump's bracket. The starter motor is dismantled in the illustration in order to show the position of the screws.

8. Loosen the screw (C) for the intake manifold stay several turns.

9. Lower the car.

10. Remove the solenoid valve's hose (A) from the intake manifold.


11. Remove the pressure sensor, inlet pipe (431) (B) from the intake manifold. Let the sensor hang in the connector.

12. Remove the cable duct's nuts (C).

13. Undo the fuel pressure regulator's hose (D) from the intake manifold.

14. Remove the SAI pump's inlet hose from the SAI pump and air cleaner.


15. Undo the EVAP canister purge valve's hose (A) from the intake manifold and fold aside.


16. Undo the brake servo's plastic hose (B) from the intake manifold.

17. Unplug the injector connectors (B).


18. Loosen the wiring harness connector from the clip (A) under the intake manifold.

19. Lift up the wiring harness to the injectors.

20. Remove the upper bracket for the dipstick tube (A) and loosen it from the oil sump, and fold it to the side.


21. Remove the intake manifold's stay (B).

22. Remove the screw (C) to the SAI pump's bracket.

23. Blow clean with compressed air between the intake manifold and cylinder head.

24. Remove the intake manifold (A). Remove the screws and nuts.



To fit


1. Clean the sealing surfaces and fit a new gasket. Make sure that the cylinder head's inlet ducts are clean.

2. Fit the intake manifold and position the cable duct, but without fitting the nuts.

3. Fit the intake manifold's stay without tightening the screw.

4. Tighten the screws and nuts for the intake manifold (A).

Tightening torque, intake manifold to cylinder head 10 Nm (7 lbf ft)


5. Fit the dipstick tube (A).


6. Tighten the intake manifold's stay (B).

Tightening torque, intake manifold, stay 22 Nm (16 lbf ft)

7. Fit the screw (C) to the SAI pump's bracket without tightening it.

8. Raise the car.

9. Fit the SAI pipe's bracket (A).


Tightening torque, intake manifold, stay 22 Nm (16 lbf ft)

10. Fit the screws (B) to the SAI pump's bracket.

Tightening torque 22 Nm (16 lbf ft)

11. Tighten the intake manifold's stay (C).

Tightening torque 22 Nm (16 lbf ft)

12. Lower the car.

13. Tighten the screw to the SAI pump's bracket.

Tightening torque 22 Nm (16 lbf ft)

14. Route the wiring harness connector under the intake manifold.

15. Fit the connector (A) to the clip (B).


16. Plug in the injectors' connector (C) to the engine's wiring harness.

17. Fit the brake servo's plastic hose (B) to the intake manifold.


18. Fit the EVAP canister purge valve's hose (A) to the intake manifold.

19. Fit the fuel pressure regulator's hose (D) to the intake manifold.


20. Fit the cable duct's nuts (C).

21. Fit the pressure sensor, inlet pipe (431) (B) to the intake manifold.

22. Fit the solenoid valve's hose (A) to the intake manifold.

23. Fit the SAI pump's intake hose to the SAI pump and air cleaner.


24. Fit the battery negative cable.

25. Fit the battery cover.

26. Fit Control module, Trionic T8 (589) .

27. Fit Throttle body actuator unit (604).

28. Carry out Procedures after reconnecting the battery.