If it's the lower intake gasket:
GASKET - INLET MANIFOLD - LOWER- FROM
99MY
Service repair no - 30.15.08
Remove
1. Remove RH and LH rocker cover gaskets. See
ENGINE, Repair. May as well replace Valve Cover Gaskets as well.
2. Disconnect multiplugs from coils.
3. Remove 2 bolts securing coils and remove coils.
4. Release leads from fuel rails and disconnect LH
and RH injector multiplugs.
5. Position absorbent cloth to catch any fuel
spillage and disconnect fuel pipe.
CAUTION: Plug the connections.
6. Remove auxiliary drive belt. See ELECTRICAL,
Repair.
7. Remove 2 nuts securing leads to alternator and
release leads.
8. Release clip securing top hose to outlet pipe and
release hose.
9. Remove 2 bolts securing alternator and remove
alternator.
10. Disconnect multiplug from compressor.
11. Remove 4 bolts securing compressor to
mounting bracket and position compressor
aside.
12. Remove 2 bolts securing PAS pump to mounting
bracket and position aside.
13. Remove bolt securing jockey pulley to mounting
bracket and remove pulley.
14. Remove 4 bolts and one nut securing mounting
bracket and remove mounting bracket .
15. Remove 4 bolts securing top hose outlet pipe
and remove outlet pipe.
16. Remove and discard ’O’ ring.
17. Disconnect ECT sensor multiplug.
18. Using the sequence shown, remove 12 bolts
securing inlet manifold.
19. Remove inlet manifold assembly.
20. Remove 2 bolts securing manifold gasket
clamps and collect gasket clamps.
21. Remove inlet manifold gasket.
22. Remove gasket seals.
Refit
23. Clean RTV from head and block notches.
24. Clean mating faces of block, head and manifold.
25. Apply RTV silicone sealant in the four ’V’ shaped
notches between the ends of the cylinder head
and the cylinder block joint.
26. Fit new gasket seals, ensure ends engage
correctly in notches.
27. Fit new manifold gasket.
28. Position gasket clamps, fit bolts but do not
tighten at this stage.
29. Position inlet manifold assembly.
NOTE: When fitting inlet manifold bolts,
tighten in reverse of removal sequence.
30. Fit manifold bolts and in the sequence shown
tighten bolts initially to 10 Nm (8 lbf.ft), then
tighten to 51 Nm (38 lbf.ft).
31. Tighten gasket clamp bolts to 18 Nm (14 lbf.ft).
32. Connect fuel pipe.
33. Connect multiplug to ECT sensor.
34. Clean top hose outlet pipe mating faces.
35. Lubricate and fit new ’O’ ring to outlet pipe.
36. Position outlet pipe, fit and tighten bolts to
22 Nm (16 lbf.ft).
37. Position mounting bracket, fit and tighten, bolts
to 40 Nm (30 lbf.ft), and nut to 10 Nm (7 lbf.ft).
38. Fit jockey pulley and tighten bolt to 50 Nm
(37 lbf.ft).
39. Clean PAS pump dowels and dowel holes.
40. Position PAS pump to mounting bracket, locate
on dowels and fit and tighten bolts to 40 Nm
(30 lbf.ft).
41. Clean compressor dowels and dowel holes.
42. Position compressor, locate on dowels and fit
and tighten bolts to 25 Nm (18 lbf.ft).
43. Connect multiplug to compressor.
44. Position alternator, fit and tighten bolts to 45 Nm
(34 lbf.ft).
45. Position top hose and secure clip.
46. Connect alternator cables, fit nuts and tighten B+
nut to 18 Nm (13 lbf.ft)max and D+ nut to 5 Nm
(3.5 lbf.ft)max. B+ and D+ are marked on the
rear of the alternator, adjacent ot each cable
connector. Fit leads to alternator and tighten
nuts.
47. Fit auxiliary drive belt. See ELECTRICAL,
Repair.
48. Connect injector multiplugs and secure leads to
fuel rail.
49. Position coils and fit bolts but do not tighten at
this stage.
50. Connect multiplugs to coils.
51. Fit rocker cover gaskets. See ENGINE, Repair.
