Intake Manifold: Service and Repair

REMOVAL





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





2. Remove the accelerator and cruise control cables.
3. Remove the engine coolant hose and throttle body.
4. Remove the P.C.V. hose and brake booster vacuum hoses.





5. Disconnect the vacuum hose connections.





6. Remove the surge tank stay.
7. Bleed off the pressure in the fuel pipe line to prevent the fuel from spilling.





8. Disconnect the connector from high pressure hose.





9. Remove the surge tank.





10. Remove the surge tank and gasket.





11. Disconnect the fuel injector harness connector.





12. Remove the delivery pipe with the fuel injector and the pressure regulator.

NOTE: When the delivery pipe is removed, be careful not to drop an injector.





13. Disconnect the wiring harness of the coolant sensor assembly.

INSPECTION
SURGE TANK AND INTAKE MANIFOLD
1. Check the surge tank and intake manifold for damage, cracking or restriction of the vacuum outlet port, water or gas passages.





2. Check for distortion on the surface using a straight edge and feeler gauge.
Standard value: 0.15 mm (0.006 inch) or less
Service limit: 0.2 mm (0.0078 inch)

INSTALLATION








1. Install the intake manifold and delivery pipe reversing the order of the removal procedure.
Tightening torque
Intake manifold: 19 - 21 Nm (190 - 210 kgf-cm, 14 - 15 ft. lbs.)
Surge tank: 15 - 20 Nm (150 - 200 kgf-cm, 11 - 14 ft. lbs.)