Intake Manifold: Service and Repair

INTAKE MANIFOLD AND THROTTLE
BODY REMOVAL AND INSTALLATION

REMOVAL
1. Relieve fuel pressure.
2. Disconnect negative cable at battery.





3. Drain cooling system.

WARNING: To help avoid danger of being burned, do not remove drain plug and radiator cap while engine and radiator are still hot. Scalding fluid and steam can be blown out under pressure if plug and cap are taken off too soon.





4. Remove air intake pipe.
5. Disconnect accelerator cable and A/T kickdown cable (for 3 A/T model) or A/T throttle cable (for 4A/T model) from throttle body, and PCV hose from PCV valve.





6. Disconnect following electric lead wires:
- EGR solenoid vacuum valve
- Ground wires from intake surge tank
- Coolant (Water) temperature gauge
- Engine coolant temperature sensor
- Injectors, Throttle Position (TP) sensor and Idle Air Control Valve (IAC) valve lead wires at the coupler
- Evaporative Emission (EVAP) canister purge valve
- A/C coolant (water) temperature switch (if equipped)
- EGR solenoid vacuum valve (for system check)





7. Disconnect following hoses:
- Brake booster hose from intake surge tank
- Canister purge hose from EVAP canister
- Engine cooling water (coolant) hose (outlet side) from IAC valve
- Radiator inlet hose from thermostat cap
- Vacuum hose for A/T. (for 3 A/T model.)
- Tank pressure control solenoid vacuum valve hose from solenoid vacuum valve (if equipped)
- Manifold differential pressure sensor hose from sensor.





8. Disconnect fuel feed hose joint. Use back-up wrench while loosening and tightening flare nut.
Disconnect fuel return hose from pipe.





9. Remove generator adjust arm stiffener.





10. Remove intake manifold stiffener, No. 1 stiffener and No. 2 stiffener with EGR pressure transducer.
11. Disconnect bypass hose of engine coolant from intake manifold.





12. Remove intake manifold with surge tank and throttle body from cylinder head, and then its gasket.

INSTALLATION
Reverse removal procedure for installation noting the followings.





- Use new intake manifold gasket.





- When installing intake manifold, install clamps at positions as shown in figure.

Tightening Torque (a): 23 Nm (17.0 ft. lbs.)





- Tighten stiffeners bolts to specified torque.

Tightening Torque (a): 50 Nm (36.5 ft. lbs.)





- Tighten fuel feed pipe flare nut to specified torque. Be sure to use back-up wrench.

Tightening Torque (a): 45 Nm (32.5 ft. lbs.)





- Adjust accelerator cable play and A/T kickdown cable (for 3 A/T model) or A/T throttle cable (for 4 A/T model) play.
- Check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not been reinstalled.
- Refill cooling system.
- Upon completion of installation, turn ignition switch ON but engine OFF and check for fuel leaks.
- Finally, start engine and check for engine coolant leaks.