Intake Manifold: Service and Repair

INTAKE MANIFOLD







REMOVAL

WARNING: To avoid the danger of being scalded, never drain the engine coolant when the engine is hot.

1. Remove engine cover (with power tool).
2. Release fuel pressure.
3. Remove air cleaner case and air duct assembly.







4. Disconnect fuel tube quick connector on engine side (The same apply to the quick connector on vehicle side excepting quick connector cap).







Using tool of quick connector release [SST: J-45488], perform the following steps to disconnect quick connector.







a. Remove quick connector cap (engine side only).
b. With the sleeve side of release facing quick connector, install release onto fuel tube.
Insert release into quick connector until sleeve contacts and goes no further. Hold the release on that position.

CAUTION: Inserting the release hard will not disconnect quick connector. Hold release where it contacts and goes no further.

d. Draw and pull out quick connector straight from fuel tube.

CAUTION: Pull quick connector holding A position in illustration.
Do not pull with lateral force applied. O-ring inside quick connector may be damaged.
Prepare container and cloth beforehand as fuel will leak out.
Avoid fire and sparks.
Be sure to cover openings of disconnected pipes with plug or plastic bag to avoid fuel leakage and entry of foreign materials.

5. Move cooling fan fluid reservoir tank.
6. Remove or disconnect intake manifold upper, wiring harnesses, brackets, vacuum hose, vacuum gallery and PCV hose and tube.

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

7. Remove electric throttle control actuator loosening fixing bolts diagonally.

CAUTION: Handle carefully to avoid any shock.







8. Loosen bolts in reverse order of illustration to remove intake manifold upper assembly with power tool.
9. Remove fuel injectors and fuel tube assembly.







10. Loosen bolts in reverse order of illustration to remove intake manifold lower assembly with power tool.




INSPECTION AFTER REMOVAL







Surface Distortion
Using straightedge and feeler gauge, inspect surface distortion of intake manifold lower and intake manifold upper.

Standard: 0.1 mm (0.004 inch)



INSTALLATION
Install in the reverse order of removal caving attention to the following:

Intake manifold lower:

Tightening Intake Manifold Lower Bolts
Tighten in numerical order as shown in the figure.

NOTE: No.7 and 8 have longer bolt length than others.

Intake manifold upper:

Tightening Intake Manifold Upper Bolts
Tighten in numerical order as shown in the figure.

NOTE: No.1 to 4 have longer bolt length than others.

Installation of Electric Throttle Control Actuator
Install intake manifold adapter gasket and electric throttle control actuator gasket so that three protrusions for installation identification do not face downward.

Tighten fixing bolts of electric throttle control actuator equally and diagonally in several steps.

After installation perform procedure in "INSPECTION AFTER INSTALLATION".


Connecting Water Hose
Install water hose so that its overlap width for connection is between 27 mm (1.06 inch) and 32 mm (1.26 inch) (target: 27 mm, 1.06 inch).


Connecting Quick Connector of Fuel Tube
Install quick connector as follows. (The steps are the same for quick connectors on both engine side and vehicle side excepting quick connector cap.)

1. Make sure no foreign substances are deposited in and around tube and quick connector, and no damage on them.







2. Thinly apply new engine oil around the fuel tube from tin end to the spool end.
3. Align center to insert quick connector straightly into fuel tube.
- Insert until the paint mark for engagement identification (white) goes completely inside quick connector so that you cannot see it from the straight side of the connected part. Use a mirror to check this where it is not possible to view directly from the straight side, such as quick connector on vehicle side.





- Insert fuel tube into quick connector until top spool is completely inside quick connector, and 2nd level spool exposes right below quick connector on engine side.

CAUTION: Hold A position in illustration when inserting fuel tube into quick connector.
Carefully align center to avoid inclined insertion to prevent damage to O-ring inside quick connector.
Insert until you hear a "click" sound and actually feel the engagement.
To avoid misidentification of engagement with a similar sound, be sure to perform the next step.

4. Pull quick connector by hand holding A position. Make sure it is completely engaged (connected) so that it does not come out from fuel tube.

NOTE: Recommended pulling force is 50 N (5.1 kg, 11.2 lbs.).







5. Install quick connector cap on quick connector joint (on engine side only).
6. Install fuel hose and tube to hose clamps.



INSPECTION AFTER INSTALLATION
After installing fuel tubes, make sure there is no fuel leakage at connections in the following steps.

a) Apply fuel pressure to fuel lines with turning ignition switch ON (with engine stopped). Then check for fuel leaks at connections.
b) Start the engine and rev it up and check for fuel leaks at connections.

- Perform procedures for "Throttle Valve Closed Position Learning" after finishing repairs.
- If electric throttle control actuator is replaced, perform procedures for "Idle Air Volume Learning" after finishing repairs.