Overhaul

INTAKE MANIFOLD

DISASSEMBLY

1. Remove the fuel pipe protector RH from the intake manifold.






2. Remove the engine ground terminal from the fuel pipe protector LH and remove the fuel pipe protector LH from the intake manifold.






3. Disconnect the vacuum hose (A) from intake manifold.
4. Disconnect the vacuum hose (B) and the connector (C) from the fuel pipe, and remove the purge control solenoid valve 1 from the intake manifold.






5. Disconnect the filter assembly.






6. Disconnect the connector from the wastegate control solenoid valve and the manifold absolute pressure sensor, and remove the solenoid valve bracket assembly from the intake manifold.






7. Disconnect the connector from the purge control solenoid valve 2, and disconnect the vacuum hose from the intake duct and the fuel pipe.
8. Disconnect the connectors from the throttle position sensor.






9. Remove the throttle body from the intake manifold.






10. Disconnect the connector from the fuel injector and tumble generator valve assembly.
- RH side






- LH side






11. Remove the PCV pipe (A), harness assembly (B), intake duct (C), brake booster vacuum hose (D) and vacuum hose (E) from the intake manifold.






12. Remove the bolt which secures the fuel injector pipe LH onto the intake manifold, and disconnect the pressure regulator vacuum hose from the intake manifold.






13. Remove the bolts which hold fuel injector pipe onto intake manifold.
- RH side






- LH side






14. Remove the fuel injector.
- RH side






- LH side






15. Remove the bolts which hold fuel pipe onto intake manifold.






16. Remove the bolt which holds fuel injector pipe RH onto intake manifold.






17. Loosen the clamp which holds the fuel hose to the fuel injector pipe RH and the fuel pipe, and then disconnect the pipe from the fuel hose.






18. Remove the fuel injector pipe and the fuel pipe.
19 Remove the tumble generator valve assembly from the intake manifold.






20. Remove the nipple from the intake manifold.






ASSEMBLY

1. Apply liquid gasket to the nipple threads, and install the nipple to the intake manifold.

Liquid gasket: THREE BOND 1105 (Part No. 004403010) or equivalent

Tightening torque: 23 N.m (2.3 kgf-m, 17.0 ft-lb)






2. Install the tumble generator valve assembly onto intake manifold.

NOTE: Use new O-rings.

Tightening torque: 8.3 N.m (0.8 kgf-m, 6.1 ft-lb)






3. Install the fuel injector pipe.
4. Connect fuel hoses to the fuel injector pipe and the fuel pipe.






5. Secure the fuel injector pipe RH to intake manifold with bolt.

Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)






6. Secure the fuel pipe to intake manifold with bolts.

Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)






7. Install the fuel injector.

NOTE: Use new O-rings, rubbers and seal rings.

- RH side






- LH side






8. Secure the fuel injector pipe to intake manifold with bolts.

Tightening torque: 19 N.m (1.9 kgf-m, 14.0 ft-lb)

- RH side






- LH side






9. Secure the fuel injector pipe LH to intake manifold with bolt, and connect the pressure regulator vacuum hose to the intake manifold.

Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)






10. Install the PCV pipe (A), harness assembly (B), intake duct (C), brake booster vacuum hose (D) and vacuum hose (E) to the intake manifold.

Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)






11. Connect the connector to the fuel injector and the tumble generator valve assembly.
- RH side






- LH side






12. Install the throttle body to the intake manifold.

NOTE: Use new O-rings.

Tightening torque: 8 N.m (0.8 kgf-m, 5.9 ft-lb)






13. Connect the connector to the throttle position sensor.






14. Connect the vacuum hose to the intake duct and the fuel pipe, then connect the connector to the purge control solenoid valve 2.

NOTE: Connect the vacuum hose as shown in the figure.






15. Install the solenoid valve bracket assembly to the intake manifold, and connect the connector to the wastegate control solenoid valve and the manifold absolute pressure sensor.

Tightening torque:
T1: 17 N.m (1.7 kgf-m, 12.5 ft-lb)
T2: 19 N.m (1.9 kgf-m, 14.0 ft-lb)






16. Connect the filter assembly.






17. Connect the vacuum hose and the connector the fuel pipe, and install the purge control solenoid valve 1 to the intake manifold.

NOTE: Connect the vacuum hose as shown in the figure.






Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)






18. Connect the vacuum hose to the intake manifold.

NOTE: Connect the vacuum hose as shown in the figure.









19. Install the fuel pipe protector LH to the intake manifold, and install the engine ground terminal to the fuel pipe protector LH.

Tightening torque: 19 N.m (1.9 kgf-m, 14.0 ft-lb)






20. Install the fuel pipe protector RH to the intake manifold.

Tightening torque: 19 N.m (1.9 kgf-m, 14.0 ft-lb)