Overhaul

Intake Manifold

DISASSEMBLY

1. Remove clamp (A) holding the fuel pipe protector RH to the engine harness, and remove the fuel pipe protector RH.






2. Remove the fuel pipe protector LH.






3. Remove the connector from the intake duct.






4. Remove the connector from the PCV hose assembly.






5. Remove purge control solenoid valve 1 (A) and purge control solenoid valve 2 (B).






6. Disconnect the connector (A) from the wastegate control solenoid valve, and disconnect the vacuum hose (B) from the intake duct.






7. Remove the solenoid valve bracket together with the wastegate control solenoid valve.






8. Remove the engine ground terminals from the intake manifold.






9. Disconnect the connector (A) from the throttle position sensor, and the connector (B) from the manifold pressure sensor.






10. Remove clip (A) holding the engine harness and vacuum hose, clip (B) holding the engine harness to the engine harness stay, and the bolt holding the engine harness to the intake manifold.






11. Remove the throttle body from the intake manifold.






12. Remove the harness band (A) which holds the engine harness to the fuel injector pipe.
- RH side






- LH side






13. Disconnect the connector from fuel injector.






14. Disconnect the connector from the tumble generator valve assembly.






15. Remove the bolts which hold fuel injector pipe.
- RH side






- LH side









16. Remove the fuel injector.






17. Remove the harness brackets holding the engine harness to the intake manifold, and remove the engine harness.






18. Loosen the clamp holding the RH side fuel hose to the fuel injector pipe RH, and remove the fuel injector pipe RH.






19. Loosen the clamp holding the LH side fuel hose to the fuel injector pipe LH, and remove the fuel injector pipe LH.






20. Remove the bolts holding the fuel pipe assembly to the intake manifold, and remove the fuel pipe assembly.






21. Remove the intake duct from intake manifold.






22. Remove the tumble generator valve assembly from the intake manifold.






23. 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)

Tightening torque:
T1: 17 N.m (1.7 kgf-m, 12.5 ft-lb)
T2: 25 N.m (2.5 kgf-m, 18.4 ft-lb)






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

NOTE: Use a new gasket.

Tightening torque: 8.25 N.m (0.8 kgf-m, 6.1 ft-lb)






3. Install the air intake duct to the intake manifold.

Tightening torque: 17 N.m (1.7 kgf-m, 12.5 ft-lb)






4. Install the fuel pipe assembly to the intake manifold.

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






5. Install the fuel injector pipe LH and connect the LH side fuel hose to the fuel injector pipe LH.






6. Install the fuel injector pipe RH and connect the RH side fuel hose to the fuel injector pipe RH.






7. Install the engine harness to the intake manifold and attach the harness brackets holding the engine harness.

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






8. Install the fuel injector.

NOTE: Use new O-rings.






9. Install the bolts which hold fuel injector pipe.
- RH side

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






- LH side

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






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






10. Connect the connector to the tumble generator valve assembly.






11. Connect the connectors to the fuel injector.






12. Secure the engine harness to the fuel injector pipe with the harness band (A).
- RH side






- LH side






13. Install the throttle body to the intake manifold.

NOTE: Use a new gasket.

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






14. Secure the engine harness and vacuum hose using the clip (A), and secure the engine harness to the engine harness stay using the clip (B), and install the bolt which holds the engine harness to the intake manifold.

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






15. Connect connector (A) to the throttle position sensor and connector (B) to the manifold pressure sensor.






16. Install the engine ground terminal to intake manifold.

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






17. Install the solenoid valve bracket together with the wastegate control solenoid valve.

Tightening torque:
T1: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
T2: 19 N.m (1.9 kgf-m, 14.0 ft-lb)






18. Connect the vacuum hose (B) to the intake duct, then connect the connector (A) to the wastegate control solenoid valve.






19. Install purge control solenoid valve 1 and purge control solenoid valve 2.

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






Tightening torque:
T1: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
T2: 16 N.m (1.6 kgf-m, 11.8 ft-lb)






20. Attach the connector to the PCV hose assembly.






21. Install the connector to the intake duct.






22. Install the fuel pipe protector LH.

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






23. Install the fuel pipe protector RH, and secure the engine harness to the fuel pipe protector RH using the clip (A).

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