Intake Manifold Collector

INTAKE MANIFOLD COLLECTOR





Removal and Installation
REMOVAL

WARNING:
^ To avoid the danger of being scalded, never drain engine coolant when the engine shot.
^ Gasket for intake manifold collector (upper) is secured together with mounting bolt for intake manifold collector (lower). Thus, even when only gasket for upper side is replaced, gasket for lower side must be also replaced.





1. Remove engine cover with power tool.
2. Disconnect water hoses from intake manifold collector (upper), attach blind plug to prevent engine coolant leakage.

CAUTION:
^ Perform this step when the engine is cold.
^ Do not spill engine coolant on drive belts.

3. Remove air cleaner case and air duct.
4. Remove electric throttle control actuator as the following: a. Disconnect harness connector.





b. Loosen mounting bolts in reverse order as shown in the figure.

CAUTION:
^ Handle carefully to avoid any shock to electric throttle control actuator.
^ Do not disassemble.

5. Remove fuel sub-tube mounting bolt to disconnect from rear of intake manifold collector (lower).
6. Disconnect vacuum hose and water hose from intake manifold collector (upper).
7. Remove EVAP canister purge volume control solenoid valve bracket mounting bolt from intake manifold collector (upper).





8. Loosen mounting bolts in reverse order of illustration to remove intake manifold collector (upper) with power tool.
9. Remove PCV hose [between intake manifold collector (lower) and rocker cover (right bank)].





10. Loosen mounting bolts in reverse order as shown in the figure, and remove intake manifold collector cover, gasket, intake manifold collector (lower) and gasket with power tool.

CAUTION: Cover engine openings to avoid entry of foreign materials.

INSPECTION AFTER REMOVAL
Surface Distortion





^ Check the surface distortion of both the intake manifold collector (upper and lower) mating surfaces with a straightedge and a feeler gauge.
Limit: 0.1 mm (0.004 inch)
^ If it exceeds the limit, replace intake manifold collector (upper and/or lower).

INSTALLATION
Note the following, and install in the reverse order of removal.

Part Installation Direction





Referring to front marks, install parts shown in figure.

Intake Manifold Collector (Lower)





Tighten mounting bolts in numerical order as shown in the figure.

NOTE: Tighten mounting bolts to secure gasket (lower), intake manifold collector (lower), gasket (upper), and intake manifold collector cover.

Intake Manifold Collector (Upper)
^ If stud bolts were removed, install them and tighten to the specified torque below.
Torque: 5.9 Nm (0.6 kg-m, 52 inch lbs.)





^ Shank length under bolt head varies with bolt location. Install mounting bolts while referring to numbers shown below and in the figure. (Bolt length does not include pilot portion.)
Bolt
M6 x 25 mm (0.98 inch): 7, 8, 10, 11, 13, 14, 15, 16, 18
M6 x 45 mm(1.77 inch): 2, 4, 5
M6 x 60 mm (2.36 inch): 1, 3, 6, 9
M6 Nut: 12, 17
^ Tighten mounting bolts in numerical order as shown in the figure.

Water Hose
^ Insert hose by 27 to 32 mm (1.06 to 1.26 inch) from connector end.
^ Clamp hose at location of 3 to 7 mm (0.12 to 0.28 inch) from hose end.

Electric Throttle Control Actuator
^ Install gasket with positioning no-protrusion surface upward or downward.





^ Tighten in numerical order as shown in the figure.
^ Perform the Throttle Valve Closed Position Learning when harness connector of electric throttle control actuator is disconnected. Refer to EC-84, Throttle Valve Closed Position Learning. Throttle Valve Closed Position Learning
^ Perform the Idle Air Volume Learning and Throttle Valve Closed Position Learning when electric throttle control actuator is replaced. Refer to EC-84, Idle Air Volume Learning. Programming and Relearning