Intake Manifold: Service and Repair

INTAKE MANIFOLD





COMPONENTS

REMOVAL





1. Remove the engine cover.





2. Disconnect the battery terminal.





3. Disconnect the air flow sensor connector and the vacuum hose from the air intake hose.
4. Remove the air cleaner assembly after removing the air intake hose clamp and fixing bolt (3ea).





5. Disconnect the crank angle sensor connector, the cam angle sensor connector, the injector harness connector, the power steering switch connector, the variable intake motor connector (2ea), the accelerator position sensor connector and the EGR solenoid connector.





6. Disconnect the injector connector after removing the injector harness bracket bolt (2ea).

CAUTION: When disconnect the injector connector, lift the fuel delivery pipe and injector assembly upward appropriately. At this time unscrew the mounting bolt to lift the fuel delivery pipe.
Reinstall the delivery pipe and injector assembly.





7. Disconnect the throttle position sensor connector, the ETS(Electronic throttle system) motor connector, the limp-home connector and the purge solenoid valve connector.





8. Disconnect the vacuum hoses between the cylinder head cover and the intake manifold. Disconnect the fuel pressure regulator vacuum hose, the purge control solenoid valve hose and the throttle body heater hose.





9. Remove the bracket of the injector harness connector, the crank angle sensor connector and the cam angle sensor connector.





10. Remove the EGR valve hose, the EGR valve mounting bolts, the EGR pipe fixing bracket bolt and the surge tank stay mounting bolts.





11. Remove the surge tank assembly after unscrewing the surge tank mounting bolts and nuts.





12. Remove the delivery pipe and injector assembly after unscrewing bolts.





13. Remove the timing belt cover.





14. Remove the water pump bracket mounting bolts and the intake manifold mounting nuts.
15. Remove the intake manifold.

INSPECTION
SURGE TANK AND INTAKE MANIFOLD
1. Check the surge tank and intake manifold for damage, cranking or restriction of the vacuum outlet port, water or gas passages.





2. Check for distortion on the surface using a straight edge and feeler gauge.
Standard value: 0.15 mm (0.006 inch) or less
Service limit: 0.2 mm (0.0078 inch)

INSTALLATION





1. Install the intake manifold with new gasket and tighten nuts in order as shown figure.
Tightening torque: 19.6 - 22.6 Nm (2.0 - 2.3 kg-m, 14.5 - 16.6 ft. lbs.)
2. Install the water pump bracket.
Tightening torque: 19.6 - 26.5 Nm (2.0 - 2.7 kg-m, 14.5 - 19.5 ft. lbs.)
3. Install the timing belt covers.
Tightening torque: 9.8 - 11.8 Nm (1.0 - 1.2 kg-m, 7.2 - 8.7 ft. lbs.)
4. Install the delivery pipe and injector assembly.
Tightening torque: 9.8 - 12.7 Nm (1.0 - 1.3 kg-m, 7.2 - 9.4 ft. lbs.)
5. Install the surge tank assembly.
Tightening torque: 14.7 - 19.6 Nm (1.5 - 2.0 kg-m, 10.8 - 14.5 ft. lbs.)
6. Install the EGR valve hose, the EGR valve mounting bolts, the EGR pipe fixing bracket bolt and the surge tank stay mounting bolts.
Tightening torque:
Surge tank stay: 14.7 - 19.6 Nm (1.5 - 2.0 kg-m, 10.8 - 14.5 ft. lbs.)
EGR pipe bracket: 14.7 - 19.6 Nm (1.5 - 2.0 kg-m, 10.8 - 14.5 ft. lbs.)
EGR valve: 16.7 - 25.5 Nm (1.7 - 2.6 kg-m, 12.3 - 18.8 ft. lbs.)
7. Install the bracket of the injector harness connector, the crank angle sensor connector and the cam angle sensor connector.
8. Reconnect the vacuum hoses between the cylinder head cover and the intake manifold. Reconnect the fuel pressure regulator vacuum hose, the purge control solenoid valve hose and the throttle body heater hose.
9. Reconnect the throttle position sensor connector, the Electronic Throttle System (ETS) motor connector, the limp-home connector and the purge solenoid valve connector.
10. Reconnect the crank angle sensor connector, the cam angle sensor connector, the injector harness connector, the power steering switch connector, the variable intake motor connector (2ea), the accelerator position sensor connector, the EGR solenoid connector and the injector connector.
11. Install the air cleaner assembly (bolt 3ea).
Tightening torque: 7.8 - 9.8 Nm (0.8 - 1.0 kg-m, 5.8 - 7.2 ft. lbs.)
12. Reconnect the air flow sensor connector and the vacuum hose to the air intake hose. And then clamp the hose with the air hose clamp.
13. Reconnect the battery terminal.
14. Install the engine cover.