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Replacing Inlet Manifold Gasket 2004 MG-ZR

Always found the better option when replacing the inlet manifold gasket is not just detached from cylinder head while new gasket is fitted, but with it removed from the vehicle, its not that much more time consuming, makes it easier to work on, and giving a better access for cleaning the  mating surfaces of the unit which requires being perfectly clean. The throttle body also removed, giving an opportunity to clean the internals.

Replacing Inlet Manifold Gasket 2004 MG-ZR

Retaining the throttle body during this project

The 4 x 8mm throttle body bolts were then removed, easier and less of a disturbance with accelerator cable still attached, safer and not actually going anywhere. On assembly it may need a new throttle body O ring MKG 100250, this will not always be required..

Coolant can now be drained off, There are several vacuum hoses and various connectors to consider during the manifold removal process, the most obvious one being the brake servo vacuum hose, others not necessarily in order are the fuel feed and fuel return hoses etc. The fuel return rail is attached to underside of manifold with 2 x 8mm bolts, which may require fitting a couple of new BAU-5325 fuel O rings on assembly.  

During removal of the inlet manifold, the underside nuts would have normally been difficult to get at, With throttle body removed it was made that much easier also givng a better reach in access, especially to each of the lower 13mm nuts, 3 on the top and 4 on the bottom.

Replacing Inlet Manifold Gasket 2004 MG-ZR

Inlet Manifold Multi Connector

Coilpack connectors were now disconnected, this part of the wiring can be withdrawn with the removal process of the inlet manifold. after the multi-connector, directly under throttle body, and with the sliding locking tab shown in the 'open position' is detached.

Replacing Inlet Manifold Gasket 2004 MG-ZR

Inlet Manifold and Throttle Body Cleaning

Prior to fitting a new manifold gasket LKJ 101110 no sealant required, the unit was cleaned internally, this needs a clean internal space for the mixing of a combined flow of fuel and air. Also as stated a good clean to the internals, and a polish to the throttle body.

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Rover 200/MG-ZR Technical and Information Pages (c) 2004-2018.

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