Intake Manifold: Service and Repair

REMOVAL




1. Remove the air breather hose connected to the throttle body.




2. Remove the accelerator cable.

3. Remove the engine coolant hose and throttle body.




4. Remove the PC.V. valve and brake boost vacuum hose.




5. Disconnect the vacuum hose connector.




6. Remove the injector cover.

7. Bleed oft pressure in the fuel pipe line to prevent fuel from spilling and then disconnect the high pressure hose.




8. Disconnect the fuel injector harness connector.




9. Remove the delivery pipe with fuel injectors and the pressure regulator.


NOTE:
When the delivery pipe is removed, do not drop the injectors.





10. Remove the intake manifold stay.




11. Remove the intake manifold.

INSPECTION

Intake Manifold And Surge Tank
1. Check the parts for damage or cracking.
2. Check for restrictions in the vacuum outlet port, water or gas passages.
3. Check for flatness using a straight edge and feeler gauge.

Standard value: 0.15 mm (0.06 in.) or less Service limit: 0.2 mm (0.0078 in.)

INSTALLATION




1. Install the intake manifold and new gasket to the specified torque.

Tightening torque
Intake manifold:

Bolt: 15-2ONm (150-120 kg.cm, 11-14 lb.ft)

Nut: 30-42Nm (300-420 kg.cm, 22-30 lb.ft)





2. Install the delivery pipe and injector assembly to the intake manifold.


NOTE:
Make certain that there is no interferences between the injectors and injector ports on the intake maniold.

3. Install the surge tank stay.


4. Connect the fuel injector connector and wiring harness and then install the cover.






5. Connect the high pressure hose.

6. Connect the vacuum hose.

Tightening Torque
Intake manifold stay and cylinder block:
18 - 25 Nm (180 - 250 kg.cm, 13 - 18 lb.ft.)

7. Connect the PCV valve and brake booster hoses.

8. Install the air breather hose.

9. Install the accelerator cable.