Intake Air Plenum: Service and Repair

REMOVAL
1. Remove the air intake surge tank.
2. Reduce the internal pressure of the high pressure fuel hose.

- Raise and support vehicle.
- Disconnect fuel pump electrical connector.
- Lower vehicle.
- Start engine and allow to idle.
- After engine has stopped, turn ignition switch to the OFF position, then disconnect battery ground cable.
- After fuel system repairs are complete, reconnect fuel pump connector.

3. Remove the high pressure fuel hose.

4. Disconnect the fuel return hose.

Fuel Rail And Injectors:

5. Remove the delivery pipe with the fuel injector.

NOTE: Be careful not to drop the injector when removing the delivery pipe.

CAUTION: Be aware that fuel may flow out when removing the injector.

INSPECTION

Intake Manifold

1. Check the intake manifold for damage, cracking, or restriction of the vacuum outlet port, water and or gas passages.





2. Check for distortion of the cylinder head mounting surface by using a straight edge and feeler gauge.

Standard value: 0.15 mm (0.006 in.) or less

Service limit: 0.3 mm (0.012 in.)

INSTALLATION





1. Attach the intake manifold gasket with the adhesive coated side faced upward toward the intake manifold.
2. Install a new insulator to the intake manifold.