Here's the view as you start, intimidating aint it. Don't worry if you label everything and take your time everything will go just fine. One common mistake is thinking "Oh I don't have to label that it's obvious where it goes" It may be clear now but if you get held up it may not be so clear a week or two from now. Believe me I've been there. Click the pic for a full size view. |
Remove the intake hose from the throttle body and disconnect it from the intercooler. This gives access to the manifold. |
With the hoses out of the way remove the cable drum (1) and the ground wires secured by its mount bolts (2). Remove the other two ground wires (3) and remove and label all hoses. Remove the wires and fuel line (4) to the cold start injector. Remove and label all the hoses attached to the manifold. There is a bolt (5) under the manifold that secures the brace, remove it and the six nuts and two bolts holding the manifold. Lift off the manifold and clean the gasket material off the mating surfaces |
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Now is a good time to inspect, clean, and replace anything that was inaccessible before. While I was in there I, cleaned oil separator (1) and replaced the motor mount (2), flame trap holder and hose (3) remember no flame trap on a turbo, and the heater hoses (4), Everything else accessible was cleaned and tested per specs in Bentley's manual. |
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Now that everything is out of the way just start at the firewall and remove the old harness and put in the new one routing it the same as the old one. I found it easier to completely pull the alternator and replace the old worn accessory bushings. This provided good access to the oil pressure sender and got rid of a potential problem with squeaky belts. |
