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Copy these instructions and print them out...sorry no diagrams to go with this, but I think it's fairly self explanatory.
Remove:
battery negative lead
throttle pulley cover
throttle cable
spark plug cover
crankcase ventilation from cylinder head
To Remove the fuel rail with injectors:
Remove:
fuel rail cover
injector connectors
2 fuel line clamps and 2 fuel rail mounting screws
install the 5 holders on injectors (holding tool, part# 999-5533-8)
remove the vaccum pipe clip from pressure regulator
put a tie strap around delivery line and injector holder to prevent twisting and leaking fuel.
carefully lift out injectors and fuel rail and place on a protective cover on top of engine.
Removing the hose and connectors
Remove;
front charge air pipe.
air cleaner (ACL) intake hose
canister purge (CP) valve hse and intake manifold
pipe from pressure regulator and place on top of engine air duct to control module box.
vacuum hose to pulsed secondary air injection system (PAIR) solenoid valve.
hose to turbo (TC) control valve from intake manifold.
idle air control (IAC) valve and throttle position (TP) sonsor connectors.
brake system servo cylninder hose
injector cable harness clamp.
Removing intake manifold:
Remove:
3 upper intake manifold screws
dipstick from intake manifold
slacken off the lower intake manifold screws
intake manifold support bracket screw
intake manifold, by lifiting it approx. 20mm to free it from engine.
Removing Knock Sensors (KS):
Remove:
the large hose on the flame trap
knock sensor (KS) connector
knock sensors (KS).
Intalling Knock Sensors (KS):
Install:
new knock sensor (KS) and tighten to 20Nm (14.75lbf-ft).
Note that front sensor is tightened to 3 O'clock and rear is tightened to half-past 5.
Install:
knock sensor (KS) connector
flame trap hose
Installing Intake Manifold:
Install:
new gasket with 4 lower intake manif. screws.
intake manifold (make sure crankcase vent. hose is not trapped between cylinder head and intake manif. when tightening).
Install:
3 upper intake manif. screws (20Nm...14.75lbf-ft).
support bracket
dipstick
Installing fuel rail:
Install:
pipe from pressure regulator
fuel rail and 2 fuel rail clamps...press clip holding the pipe from the pressure regulator into place.
new screws and tighten to 10Nm (7.4lbf-ft)
remove injector holders
injector connectors. Make sure each has, and is fitted with a rubber seal.
injector cable harness clamp.
fuel rail cover.
Reinstalling hoses and connectors:
Install:
idle air control (IAC) valve and throttle position (TP) sonsor connectors.
brake sysgem servo cylinder hose.
turbo (TC) control valve hose to intake manif.
canister purge (CP) valve hose.
vacuum hose to pulsed secondary air injection system (PAIR) solenoid valve
hose for crankcase vent. to intake manif.
front charge air pipe.
Installing:
Install:
air cleaner (ACL) intake hose
throttle cable
throttle pulley cover.
battery negative lead
crankcase vent. to cylinder head- use new clamp.
spark plug cover.
air duct to control module box.
I think that's it....good luck!
--
1998 S70 T5 Emarald Green Metallic, 2004 V70 2.5T Ruby Red, Previous Owner of Black '94 850 Turbo Wagon. My cars have been running so well lately they've got me worried.
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