Intake Manifold Removal and Installation

Intake Manifold: Removal and Installation

CAUTION:

Do not remove or disassemble parts unless instructed as shown.

Removal

1) Release fuel pressure. Refer to [Fuel Pressure Check: QR25DE] Testing and Inspection.
2) Disconnect battery negative terminal. Refer to [Battery: Removal and Installation] Removal and Replacement.
3) Partially drain engine coolant. Refer to [Changing Engine Coolant] Service and Repair.
4) Remove air cleaner case, air cleaner filter and air duct and resonator assembly. Refer to [Air Cleaner and Air Duct: Exploded View] Exploded View.
5) Disconnect water hoses from electric throttle control actuator.

CAUTION:
- Perform this step when engine is cold.
- Do not spill engine coolant on drive belt.

6) Remove mass air flow sensor from intake manifold.

CAUTION:
Handle the mass air flow sensor with care:
- Do not shock it.
- Do not disassemble it.
- Do not touch the internal sensor.

7) Remove quick connector cap, and disconnect quick connector at the engine side. Refer to [Air Cleaner and Air Duct: Exploded View] Removal and Installation.





8) Remove air duct. Refer to Exploded View.
9) Remove electric throttle control actuator as follows:
a) Disconnect harness connector.
b) Loosen bolts in reverse order as shown, and remove electric throttle control actuator and gasket.






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

10) Disconnect harness, vacuum hoses and PCV hoses from intake manifold, and move them aside.
11) Remove intake manifold support.
12) Loosen nuts and bolts in reverse order as shown, and remove intake manifold, fuel tube protector and gasket.






CAUTION:
- Cover engine openings to avoid entry of foreign materials.
- Do not disassemble intake manifold.

NOTE:
Disregard No. 6 when loosening.

13) Remove EVAP canister purge volume control solenoid valve and vacuum hose adapter from intake manifold, if necessary.
14) Disconnect sub-harness from fuel injector. Refer to [Throttle Valve Closed Position Learning] Removal and Installation.
15) Remove fuel tube and fuel injector assembly from intake manifold. Refer to Removal and Installation.

Installation

Installation in the reverse order of removal.

Intake Manifold and Fuel Tube Protector

- If stud bolts were removed, install them and tighten to the specified torque below.






- Tighten in numerical order as shown.






NOTE:
No. 6 means double tightening of bolt No. 1.





Electric Throttle Control Actuator

- Tighten bolts equally and diagonally in several steps and in numerical order as shown.





- Perform the "Throttle Valve Closed Position Learning" when harness connector of electric throttle control actuator is disconnected. Refer to 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 [Idle Air Volume Learning] Idle Air Volume Learning.

Inspection after Installation

- Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level. Refer to [Recommended Fluids and Lubricants [for USA and Canada] [1][2]Maintenance ] (United States and Canada) or [Recommended Fluids and Lubricants [for Mexico] ] (Mexico).
- Use procedure below to check for fuel leakage.
- Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
- Run engine to check for unusual noise and vibration.

NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal and installation, slack in the guide may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after hydraulic pressure rises.

- Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gas, or any oils/fluids including engine oil and engine coolant.
- Bleed air from passages in lines and hoses, such as in cooling system.
- After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to specified level, if necessary.
- Summary of the inspection items:






*Power steering fluid, brake fluid, etc.