Thank you for your valuable information. I have a few questions about the manifold process. My manifold bolts are very tight. I want to try lubricating them with WD-40 a day in advance and then removing them when the engine is cold. However, one of the eight upper bolts on the manifold is already stripped. What can I do about this?
The top 8 upper bolts are captive and 10mm so a good six sided socket is the best tool for the job, no WD-40 should be needed, they screw into a brass collet which in turn is pressed into the plastic cam cover.
Crack open the 8 bolt/screws, then next crack open the lower four 11mm nuts, and one 11mm bolts to the left of the manifold.
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Next undo and remove the EGR special clamp.
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Prise out the rubber grommet from the side of the manifold that goes to the fuel rail.
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Move the two hoses from the side of the manifold and then press the spring clip and push down the MAP sensor plug with a screwdriver.
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All the manifold bolts and nuts are now ready to be removed, remembering the top ones are captive.
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hook out the nuts.
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Remove the left long bolt.
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Manifold is now ready to lift from the engine.
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Don't worry that the engine bay looks different the photo are from a Rover 75 diesel with the same engine, regarding the manifold removal.
Hopefully the manifold and EGR will not be as bad as this one below, mind i have seen worse.
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MAP sensor may look like this one.
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It needs to look like this.
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Wipe them clean with a rag soaked in brake cleaner, no poking down the hole etc.
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Manifold and EGR may well need a cleaning out.
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EGR when i used to do them
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