Intake Manifold: Service and Repair

Removal
1. Open the engine compartment and fit paintwork protection sheets.
2. WARNING: BEFORE PROCEEDING, IT IS ESSENTIAL THAT THE WARNINGS ARE READ AND UNDERSTOOD.

Carefully remove the engine covers, taking care not to damage the plastic fixings or the rubber inserts.





3. Depressurize the fuel system.
Ensure that the ignition is switched off and remove the valve cap from the fuel cross-over pipe.
Place a cloth under the valve to collect any spillage.
Place a closed container, suitable for collecting fuel, adjacent to the vehicle. Remove the lid.





4. Connect the fuel injection pressure test equipment 310-058 (or other suitable type). Insert the drain/bleed tube into the fuel container. Follow the manufacturer's instructions and depressurize the fuel system.
5. Store the drained fuel safely and ensure that the lid is closed securely. Remove the equipment and discard the cloth from beneath the valve. install the valve cap.
6. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors remain open until after the battery has been disconnected.





7. Disconnect the battery ground cable.
Remove the battery cover.





8. Disconnect the breather pipe from Bank 1 camshaft cover.
Disconnect the breather pipe from the stub pipe.
Remove and discard the O-ring seal from the breather pipe.
9. Disconnect the air flow meter multi-plug.
10. Cut and remove the strap which secures the vacuum pipe to the induction elbow.





11. Disconnect the intake tube from the throttle body.
Remove the two bolts which secure the intake tube to the throttle body.
Disconnect the intake tube from the throttle body.





12. Disconnect the air cleaner cover.
Remove the five Clips which secure the air cleaner cover.





13. Remove the intake tube/air flow meter/air cleaner cover assembly.
Remove the intake tube/air flow meter/air cleaner cover assembly.
Remove and discard the rubber seal; air intake tube to throttle body.





14. Disconnect the multi-plugs from the throttle body.
Disconnect the throttle body motor multi-plug.
Disconnect the two potentiometer multi-plugs, one each side of the throttle.
Disconnect the vacuum pipe elbow from the throttle actuator.





15. Disconnect the throttle inner cable.
Turn the throttle pulley to the fully open position.
Disconnect the throttle inner cable from the pulley.





16. Disconnect the throttle outer cable.
Remove the throttle cable adjusting nut from the outer cable.
Remove the cable from the adjustment bracket.





17. Disconnect the coolant hoses from the throttle body.
Release the clip which secures the coolant return hose and disconnect the hose. Install a blanking plug to the hose to prevent water leakage.
Release the clip which secures the coolant feed hose and disconnect the hose. Install a blanking plug to the hose to prevent water leakage.





18. Disconnect the multi-plug, located on the bracket under the left side of the throttle body.





19. Remove the throttle body securing bolts.





20. Remove the throttle body.
Remove the throttle body from the induction elbow.
Remove and discard the throttle body gasket.





21. Release the induction elbow support; working from the right hand side.
Disconnect the vacuum pipe from the center of the induction elbow.
Remove the upper bolt from the induction elbow support bracket.





22. Release the induction elbow support; working from the left hand side.
Disconnect the vacuum pipe from the front of the induction elbow.
Disconnect the engine breather T-piece from the induction elbow.
Remove the upper bolt from the induction elbow support bracket.
Loosen, but do not remove, the lower two bolts at the induction elbow support bracket.





23. Disconnect the electrical connector from each fuel injector.





24. Disconnect the fuel feed hose.
Disconnect the fuel feed hose at the Quick Fit connector, using special tool 310-044.





25. Disconnect the fuel return hose.
Disconnect the fuel return hose at the Quick Fit connector, using special tool 310-054.





26. Remove the intake manifold.
Remove the ten bolts which secure the intake manifold.
Remove the intake manifold





27. Remove and discard the eight seals from the intake manifold ports.





28. Remove the fuel pressure regulator from the manifold.
Remove the two bolts which secure the pressure regulator.
Remove the pressure regulator.
Remove and discard the regulator O-ring seal.





29. Remove the fuel feed pipe from the manifold.
Remove the two bolts which secure the fuel feed pipe to the intake manifold.
Remove the fuel feed pipe.
Remove and discard the pipe O-ring seal.





30. Remove the fuel cross over elbow from the intake manifold.
Remove the one bolt each side which secures the cross over elbow.
Remove the elbow from the manifold.
Remove and discard the O-ring seal.





31. Remove the fuel injectors.
Remove the securing screws from each fuel injector.
Remove the injector clamping plates.





32. Remove the injectors from the manifold; use special tool 303-539 if necessary.





33. Remove and discard the sixteen sealing rings from the injectors.





34. Remove the throttle induction elbow from the intake manifold.
Remove the seven bolts which secure the throttle induction elbow.
Remove the elbow.
Remove the induction elbow seal from the manifold.

Installation
1. Clean all parts and relevant mating faces.





2. Install the fuel pressure regulator to the manifold.
Lubricate and install a new O-ring seal to the regulator.
Install the pressure regulator to the manifold.
Install the two bolts which secure the pressure regulator. Tighten to 8-12 Nm.





3. Install the fuel feed pipe to the manifold.
Lubricate and install a new O-ring seal to the feed pipe.
Install the feed pipe to the manifold.
Install the two bolts which secure the feed pipe. Tighten to 8-12 Nm.





4. Install the fuel cross over elbow to the intake manifold.
Lubricate and install new O-ring seals to the cross over elbow.
Install the cross over elbow to the manifold.
Install the one bolt each side which secures the cross over elbow. Tighten to 8-12 Nm.





5. Install the sealing rings to the fuel injectors.
Lubricate and install the sixteen (two to each injector) new sealing rings.





6. Install the fuel injectors to the intake manifold.
Locate the injectors into the manifold.
Position the injector clamping plates.
Install the securing screws for each fuel injector. Tighten to 4-6 Nm.





7. Install the throttle induction elbow to the intake manifold.
Install a new induction elbow seal to the manifold.
Install the elbow.
Install the seven bolts which secure the throttle induction elbow. Tighten to 18-24 Nm.
8. Install the Manifold Assembly to the Engine, as follows.





9. Install eight new seals to the intake manifold ports.





10. Install the intake manifold to the engine.
Install the intake manifold.
Install the ten bolts which secure the intake manifold. Tighten to 20-22 Nm.





11. Connect the fuel feed hose.
Connect the fuel feed hose at the Quick Fit connector. Ensure that the hose is fully seated to the feed pipe.





12. Connect the fuel return hose.
Connect the fuel return hose at the Quick Fit connector. Ensure that the hose is fully seated to the feed pipe.





13. Reconnect the electrical connector to each fuel injector.





14. Install the induction elbow support; working from the left hand side.
Install the upper bolt to the induction elbow support bracket. Tighten to 16-20 Nm.
Tighten the lower two bolts at the induction elbow support bracket. Tighten to 16-20 Nm.
Connect the engine breather T-piece to the induction elbow.
Connect the vacuum pipe to the front of the induction elbow.





15. Install the induction elbow support; working from the right hand side.
Install the upper bolt to the induction elbow support bracket. Tighten to 16-20 Nm.
Reconnect the vacuum pipe to the center of the induction elbow.





16. Install the throttle body.
Install a new gasket to the throttle body.
Position the throttle body to the induction elbow.





17. Install the throttle body securing bolts. Tighten to 18-24 Nm.





18. Reconnect the multi-plug, located on the bracket under the left side of the throttle body.





19. Connect the coolant hoses to the throttle body.
Remove the blanking plugs from the hoses.
Connect the coolant feed hose and secure with the clip.
Connect the coolant return hose and secure with the clip.





20. CAUTION: Under no circumstances may the quadrant be held clear of the throttle stop by cable tension.

Install the throttle cable and ensure that there is neither tension nor slack in the cable
Tighten the locknut without altering the setting or introducing twist into the cable outer. Check the kickdown setting using the PDU. For scan tool procedure, refer to Throttle Cable Renew (Adjust).





21. Reconnect the multi-plugs to the throttle body.
Connect the throttle body motor multi-plug.
Connect the two potentiometer multi-plugs, one each side of the throttle.
Connect the vacuum pipe elbow to the throttle actuator.





22. Install the intake tube/air flow meter/air cleaner cover assembly.
Install a new rubber seal, air intake tube to throttle body.
Install the intake tube/air flow meter/air cleaner cover assembly.





23. Reconnect the air cleaner cover.
Install the five clips which secure the air cleaner cover.





24. Connect the intake tube to the throttle body.
Connect the intake tube to the throttle body.
Install the two bolts which secure the intake tube to the throttle body. Tighten to 4-5 Nm.
25. Reconnect the air flow meter multi-plug.
26. Install a new strap to secures the vacuum pipe to the induction elbow.





27. Connect the breather pipe to Bank 1 camshaft cover.
Install a new O-ring seal to the breather pipe.
Reconnect the breather pipe to the stub pipe.
28. Carefully install the engine covers, taking care not to damage the plastic fixings or the rubber Inserts.
29. Connect the battery ground cable. Install the battery cover.
30. Check for leaks and that all pipes are securely connected. Remove the protection sheets, close the engine compartment, luggage compartment and doors.