Intake Manifold: Service and Repair
REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY
CAUTION: Work must be started after approx. 20 seconds or longer from the time the ignition switch is turned to the LOCK" position and the negative (-) terminal cable is disconnected from the battery.
2. DRAIN ENGINE COOLANT
3. DISCONNECT THROTTLE CABLE FROM THROTTLE BODY AND BRACKET (A/T)
4. DISCONNECT ACCELERATOR CABLE AND BRACKET FROM THROTTLE BODY AND AIR INTAKE CHAMBER
5. REMOVE AIR CLEANER CAP. AIR FLOW METER AND AIR CLEANER HOSE
(a) Disconnect the air flow meter connector.
(b) Disconnect the air hoses.
(c) Loosen the air cleaner hose clamp bolt.
(d) Disconnect the air cleaner cap clips.
(e) Remove the air cleaner cap and air flow meter together with the air cleaner hose.
6. DISCONNECT HOSES AND CONNECTORS
(a) PCV hoses
(b) Vacuum sensing hose
(c) Water by-pass hoses
(d) Fuel pressure VSV hose
(e) Emission control vacuum hoses
(f) ISC connector
(g) Throttle position sensor connector
(h) EGR gas temp. sensor connector (CALIF. only)
7. REMOVE NO.1 RH ENGINE MOUNTING STAY
- Remove the three bolts and mounting stay.
8. DISCONNECT COLD START INJECTOR CONNECTOR
9. DISCONNECT COLD START INJECTOR TUBE
10. DISCONNECT HOSES AND PARTS
(a) Brake booster vacuum hose
(b) PS vacuum and air hoses
(c) Cruise control vacuum hose
(d) Ground strap connector
(e) Wire harness clamp
- Remove the nut, and disconnect the wire harness clamp
11. DISCONNECT WIRE HARNESS CLAMP
- Remove the nut and disconnect the wire harness.
12. DISCONNECT EGR PIPE
13. REMOVE NO.1 ENGINE HANGER AND AIR INTAKE CHAMBER STAY
(a) Remove the two bolts and No.1 engine hanger.
(b) Remove the bolt, and disconnect the air intake chamber stay from air intake chamber
14. REMOVE AIR INTAKE CHAMBER
- Remove the two bolts, nuts, air intake chamber and gasket.
15. DISCONNECT CONNECTORS
(a) Cold start injector connector
(b) Water temperature sensor connector
(c) Six injector connectors
16. DISCONNECT WIRE HARNESS CLAMPS FROM LH DELIVERY PIPE
- Disconnect the three wire harness clamp.
17. DISCONNECT FUEL INLET AND TWO RETURN HOSES
(a) Disconnect the fuel return hoses from the fuel pres sure regulator and No.1 fuel pipe.
(b) Disconnect the fuel inlet hose from the fuel filter.
18. REMOVE NO.2 FUEL PIPE
- Remove the two union bolts, four gaskets and No.2 fuel pipe.
19. REMOVE DELIVERY PIPES AND INJECTORS
(a) Remove the two bolts and LH delivery pipe together with three injectors.
NOTE: Be careful not to drop the injectors, when removing the delivery pipe.
(b) Remove the three bolts and RH delivery pipe with the No.1 fuel pipe and three injectors.
NOTE: Be careful not to drop the injectors, when removing the delivery pipe.
(c) Pull out the six injectors from the delivery pipes.
(d) Remove the six insulators and four spacers from the intake manifold.
INSTALL
1. INJECTORS AND DELIVERY PIPES
(a) Install a new grommet to the injector.
(b) Apply a light coat of gasoline to a new 0-ring and install it to the injector.
(c) While turning the injector left and right install it to the delivery pipes. Install the six injectors.
(d) Place the six insulators and four spacers in position on the intake manifold.
(e) Place the three injectors together with the RH delivery pipe and No.1 fuel pipe in position on the intake manifold.
(f) Place the three injectors together with the LH delivery pipe in position on the intake manifold.
(g) Check that the injectors rotate smoothly.
NOTE: If injectors do not rotate smoothly, the probable cause is incorrect installation of 0-rings. Replace the 0-rings.
(h) Position the injector connector upward.
(i) Install the five bolts.
Torque: 130 kg-cm (9 ft-lb, 13 N.m)
2. INSTALL NO.2 FUEL PIPE
- Install the No.2 fuel pipe with four new gaskets and the union bolts as shown in the illustration.
Torque: 330 kg-cm (24 ft-lb, 32 N.m)
3. CONNECT FUEL INLET AND RETURN HOSES
(a) Connect the inlet hose to the fuel filter with two new gaskets and union bolt.
(b) Connect the two return hoses to the pressure regulator and No.1 fuel pipe.
4. CONNECT THREE WIRE HARNESS CLAMPS TO LH DELIVERY PIPE
5. CONNECT CONNECTORS
(a) Six injector connectors
(b) Cold start injector connector
(c) Water temperature connector
6. INSTALL AIR INTAKE CHAMBER
- Install a new gasket and the air intake chamber with the two bolts and nuts.
Torque: 440 kg-cm (32 ft-lb, 43 N.m)
7. CONNECT EGR PIPE
Torque: 800 kg-cm (58 ft-lb, 78 N.m)
8. CONNECT WIRE HARNESS CLAMP
- Connect the wire harness clamp with the nut.
9. INSTALL NO.1 ENGINE HANGER AND AIR INTAKE CHAMBER STAY
(a) Connect the air intake chamber stay with the two bolts.
Torque: 380 kg-cm (27 ft-lb, 37 N.m)
(b) Install the No.1 engine hanger with the two bolts.
Torque: 380 kg-cm (27 ft-lb, 37 N.m)
10. CONNECT HOSES AND PARTS
(a) Wire harness clamp
- Connect the wire harness clamp with the nut.
(b) Brake booster vacuum hose
(c) PS vacuum and air hoses
(d) Cruise control vacuum hose
(e) Ground strap connector
11. CONNECT COLD START INJECTOR TUBE
12. CONNECT COLD START INJECTOR CONNECTOR
13. INSTALL NO.1 RH ENGINE MOUNTING STAY
- Install the mounting stay with the three bolts.
Torque: 530 kg-cm (38 ft-lb, 52 N.m)
14. CONNECT CONNECTORS AND HOSES
(a) ISC connector
(b) Throttle position sensor connector
(c) EGR gas temp. sensor connectors (CALIF. only)
(d) PCV hoses
(e) Vacuum sensing hoses
(f) Water by-pass hoses
(g) Fuel pressure VSV hose
(h) Emission control vacuum hoses
15. INSTALL AIR CLEANER CAP, AIR FLOW METER AND AIR CLEANER HOSE
(a) Connect the air cleaner hose, and install the air cleaner cap and air flow meter with the four clips.
(b) Tighten the air cleaner hose clamp bolt.
(c) Connect the air hoses.
(d) Connect the air flow meter connector.
16. CONNECT ACCELERATOR CABLE AND BRACKET TO THROTTLE BODY AND AIR INTAKE CHAMBER
17. CONNECT THROTTLE CABLE TO THROTTLE BODY AND BRACKET, AND ADJUST IT (A/T)
18. CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY
19. FILL WITH COOLANT
20. CHECK FOR FUEL LEAKAGE