Turbo inlet manifold
- Thread starter tref
- Start date
chrisg
Member
Hi Tref,
Sorry in replying to this, but to remove the inlet manifold on a 220 turbo:
1. Remove the pipework from the intercooler to the throttle body.
2. Remove the throttle cable - I've found the easiest way to do this is to unhook the cable from the throttle body then undo the 2 x 10mm bolts that hold the stay onto the manifold.
3. Remove the two fuel pipes, the high pressure feed = front on the fuel rail = 17mm nut, then the low pressure return at the back of the fuel rail = small flat screw driver.
4. Unplugt the plug leads an moverr them to one side
5. The injectors are held into the fuel rail by 4 x square 3 sided clips, remove these and place to one side.
6. The fuel rail is held on by 4 x 10mm bolts, 2 x hold it onto the cam tower, 2 into the inlet manifold - these can be tricky to get at
7. There are several pipes that need to be removed from the inlet manifold. On your 220 turbo there is a single, double length banjo bolt with two pipes (one of which = the DME feed), remove the banjo bolt. Inside the 'arms' on the inlet manifold are two vacuum feed pipes - should easiy come undo with a screwdriver, one = the vacuum feed for the brake servo the other = the byepass pipe for the idle control valve.
8. You now need to release the 8 x 6mm hex head inlet manifold bolts. Clarks has a recommendation for 'waking' these bolts up If they haven't been removed for sometime, it's easy to round the heads off as they're quite soft.- insert the appropriate hex drive with a short extension bar and give it hard tap with a hammer.
9. Once woken up, you can remove all 8 of thes an place to one side
10. The final step (unless I've missed something), is to remove the bolts that support the inlet manifold = 2 x 5mm hex drives that are vertical, 13mm bolt at the front of the manifold (don't remove it completely just undo as the suppor is slotted) oh and the dipstick support bolt = 10mm on the RHS of the manifold as you look at it, just above the turbo
11. I knew I forget something, undo the bolt that holds the bracket at the end of the manifold nearest the bulk head, which supports the two hall sensors.
I think that's all, but I could be wrong and I don't have the car to reference !
Sorry in replying to this, but to remove the inlet manifold on a 220 turbo:
1. Remove the pipework from the intercooler to the throttle body.
2. Remove the throttle cable - I've found the easiest way to do this is to unhook the cable from the throttle body then undo the 2 x 10mm bolts that hold the stay onto the manifold.
3. Remove the two fuel pipes, the high pressure feed = front on the fuel rail = 17mm nut, then the low pressure return at the back of the fuel rail = small flat screw driver.
4. Unplugt the plug leads an moverr them to one side
5. The injectors are held into the fuel rail by 4 x square 3 sided clips, remove these and place to one side.
6. The fuel rail is held on by 4 x 10mm bolts, 2 x hold it onto the cam tower, 2 into the inlet manifold - these can be tricky to get at
7. There are several pipes that need to be removed from the inlet manifold. On your 220 turbo there is a single, double length banjo bolt with two pipes (one of which = the DME feed), remove the banjo bolt. Inside the 'arms' on the inlet manifold are two vacuum feed pipes - should easiy come undo with a screwdriver, one = the vacuum feed for the brake servo the other = the byepass pipe for the idle control valve.
8. You now need to release the 8 x 6mm hex head inlet manifold bolts. Clarks has a recommendation for 'waking' these bolts up If they haven't been removed for sometime, it's easy to round the heads off as they're quite soft.- insert the appropriate hex drive with a short extension bar and give it hard tap with a hammer.
9. Once woken up, you can remove all 8 of thes an place to one side
10. The final step (unless I've missed something), is to remove the bolts that support the inlet manifold = 2 x 5mm hex drives that are vertical, 13mm bolt at the front of the manifold (don't remove it completely just undo as the suppor is slotted) oh and the dipstick support bolt = 10mm on the RHS of the manifold as you look at it, just above the turbo
11. I knew I forget something, undo the bolt that holds the bracket at the end of the manifold nearest the bulk head, which supports the two hall sensors.
I think that's all, but I could be wrong and I don't have the car to reference !
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