Installation instructions of plugs for the plastic-aluminum inlet manifold

for 1.9 JTDM engines (Fiat, Alfa Romeo, Lancia) and 1.9 CDTI (Opel, Saab).

1. Unscrew the tumble flap actuator and the plastic cover of the control mechanism, to facilitate
access for dismantling swirl flaps.
2. As the mechanism that controls the tumble flaps operation is made of plastic, it very often
happens that the toothed bar and the gears are damaged.

3. Unscrew the manifold's plastic part from the aluminum part and separate both parts.
4. Remove the swirl flaps and then wash your manifold and carefully clean all holes left after
dismantling the swirl flaps.
 5. Insert the pugs using a small press or a small hummer, being careful not to damage the
manifold. Do not remove any seals of swirl flaps that additionally seal the connection.

6. Reassemble the manifold with the swirl flap actuator and the bracket at their places.
7. Mount the manifold according to the manufacturers' instructions.