Intake Manifold: Service and Repair

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





3. Drain coolant.

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 cleaner assembly.





5. Disconnect following electric lead wires:
- EGR solenoid vacuum valve
- ISC actuator
- Ground wires from intake manifold
- Fuel injector
- TP sensor
- EFE heater.





6. Disconnect fuel return and feed hoses from fuel pipe.
7. Disconnect coolant hoses from throttle body and intake manifold.
8. Disconnect following vacuum hoses.
- Canister purge hose from intake manifold.
- MAP sensor hose from intake manifold.
- Brake booster hose from intake manifold.
9. Disconnect PCV hose from intake manifold.
10. Disconnect accelerator cable from throttle body.
11. Disconnect other connected to throttle body and intake manifold, if any.
12. Remove intake manifold with throttle body from cylinder head.
13. Remove throttle body from intake manifold.

INSTALLATION
1. Install throttle body to intake manifold.
2. Install intake manifold gasket to cylinder head. Use a new gasket.





3. Install intake manifold with throttle body to cylinder head.
- Install clamps as shown in figure, and tighten bolts and nuts to specification.

Tightening Torque (a): 18 - 28 Nm (13.5 - 20.0 ft. lbs.)





4. Connect PCV hose to intake manifold.
5. Connect vacuum hoses.
6. Connect coolant hoses.
7. Connect fuel return and feed hoses to fuel pipes.





8. Connect electric lead wires.
9. Connect accelerator cable to throttle body.
10. Install air cleaner assembly to throttle body.
11. Check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not been reinstalled.
12. Refill cooling system.
13. Connect negative cable at battery.
14. Upon completion of installation, start engine and check for fuel leaks and engine coolant leaks.
After warming up engine, adjust accelerator cable play to specification.