Note: A new gasket will be required on refitting.

Carburettor models
Removal
1 Disconnect the battery negative lead.

2 Remove the air cleaner as described in Part A of this Chapter.

3 Refer to Chapter 1 and drain the cooling system.

4 Remove the carburettor as described in Part A of this Chapter according to type.

5 Disconnect the manifold coolant hoses.

6 Make a careful note of all vacuum connections at the vacuum switches and solenoids and disconnect them.

7 Where applicable disconnect the switch wiring multi-plugs after noting their locations.

8 Undo the manifold retaining nuts and withdraw the manifold from the cylinder head studs. Recover the gasket.

Refitting
9 Refitting is the reverse sequence to removal but use a new gasket and ensure that the mating faces are clean. On completion refill the cooling system as described in Chapter 1.

XR3i and XR3i Cabriolet models with mechanical (Bosch K- and KE-Jetronic) fuel injection Removal
10 Disconnect the battery negative lead.

11 Remove the warm-up regulator, throttle housing, fuel injectors and cold start valve as described in Part B of this Chapter.

12 Drain the cooling system (Chapter 1).

13 Make a note of the vacuum hose, crankcase ventilation hose and wiring multiplug locations as applicable and disconnect them.

14 Disconnect the coolant hoses at the manifold intermediate flange.

15 Check that all wiring and hoses have been disconnected from above and below the manifold, then undo the retaining nuts.

16 Withdraw the manifold and intermediate flange together with their gaskets.

Refitting
17 Refitting is the reverse sequence to removal, but use a new gasket on each side of the intermediate flange. Refit the cold start valve, fuel injectors, throttle housing and warm-up regulator as described in Part B of this Chapter, and on completion refill the cooling system as described in Chapter 1.

RS Turbo models (1985 to May 1986) Removal
18 Disconnect the battery negative lead.

19 Remove the throttle housing, fuel injectors and cold start valve as described in Part B of this Chapter.

20 Drain the cooling system (Chapter 1).

21 Disconnect the crankcase ventilation hose and vacuum hose from the top of the plenum chamber.

22 Disconnect the vacuum servo hose from the side of the plenum chamber.

23 From below the inlet manifold remove the auxiliary air device as described in Part B of this Chapter, then disconnect the thermo-time switch and temperature sensor wiring multiplugs after noting their locations.

24 Remove the oil cooler-to-inlet manifold connecting hose.

25 From above, undo the bolts and remove the plenum chamber support bracket.

26 Undo the nuts and remove the inlet manifold and plenum chamber from the cylinder head. Recover the gasket.

27 If required undo the nuts and separate the plenum chamber from the inlet manifold.

Recover the gaskets.

Refitting
28 Refitting is the reverse sequence to removal, but use new gaskets on all flange joints. Refit the auxiliary air device, cold start valve, fuel injectors and throttle housing as described in Part B of this Chapter, and refill the cooling system as described in Chapter 1.

RS Turbo models (May 1986-on) Removal
29 Disconnect the battery negative lead.

30 Remove the throttle housing, fuel injectors, cold start valve and auxiliary air device as described in Part B of this Chapter.

31 Drain the cooling system (Chapter 1).

32 Disconnect the crankcase ventilation hose and vacuum hose from the top of the manifold and the vacuum servo hose from the side.

33 From beneath the manifold disconnect the thermo-time switch and temperature sensor wiring multi-plugs after noting their locations, and the coolant hoses from the intermediate flange.

34 Remove the oil cooler-to-manifold connecting hose.

35 Undo the retaining nuts and withdraw the manifold and intermediate flange together with their gaskets.

Refitting
36 Refitting is the reverse sequence to removal, but use a new gasket on each side of the intermediate flange. Refit the auxiliary air device, cold start valve, fuel injectors and throttle housing as described in Part B of this Chapter and on completion refill the cooling system as described in Chapter 1.

Central Fuel Injection (CFI) engine models
37 Remove the CFI unit as described in Part C of this Chapter.

38 The remainder of the procedure is similar to that described previously in this Section for carburettor engine models.

Electronic Fuel Injection (EFI) engine models
Removal
39 Depressurise the fuel system as described in Part D of this Chapter.

40 Disconnect the battery negative lead.

41 Remove the air inlet ducting, and disconnect the throttle cable from the throttle linkage (see Part A of this Chapter).

42 Remove the fuel rail and fuel injectors as described in Part D of this Chapter.

43 Noting their locations, disconnect the coolant, vacuum and breather hoses from the manifold.

44 Disconnect the wiring multi-plugs from the engine sensors at the inlet manifold.

45 Undo the retaining bolts, and withdraw the manifold from the cylinder head. Where applicable, note the location of the engine lifting bracket and/or earth lead. Remove the gasket.

Refitting
46 Commence refitting by cleaning all traces of old gasket from the mating faces of the manifold and the cylinder head.

47 Refitting is the reversal of removal, using a new gasket. Refit the remainder of the components with reference to the appropriate Parts of this Chapter.