Intake Manifold: Service and Repair

INTAKE MANIFOLD (INTAKE AIR SURGE TANK)

REMOVAL

1. DRAIN COOLANT
2. REMOVE FRONT FENDER APRON SEAL RH
3. REMOVE V-BANK COVER SUB-ASSY
4. REMOVE RADIATOR HOSE INLET
5. REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/ FRONT SUSPENSION BRACE UPPER CENTER)
6. REMOVE AIR CLEANER ASSEMBLY WITH HOSE
7. REMOVE INTAKE AIR SURGE TANK
a. Disconnect the throttle position sensor connector.
b. Disconnect the throttle control motor sensor connector.





c. Disconnect the 2 water by-pass hoses.





d. Disconnect the purge hose.





e. Disconnect the hoses and remove the nut.





f. Remove the 2 bolts and surge tank stay No. 2.





g. Remove the 2 bolts and No.1 engine hanger.
h. Remove the 2 bolts and surge tank stay No. 1.
i. Disconnect the engine wire from emission control valve set.
j. Remove the 2 nuts and emission control valve set.





k. Using an 8 mm socket hexagon wrench, remove the 4 bolts, 2 nuts, emission control valve bracket and intake air surge tank.


INSTALLATION





1. INSTALL INTAKE AIR SURGE TANK
a Using an 8 mm hexagon wrench, install a new gasket, the air intake chamber assembly and the emission control bracket with the 4 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.
Torque: 28 Nm (286 kgf-cm, 21 ft-lbf)
b. Install the emission control valve set with the 2 nuts.
Torque: 8 Nm (82 kgf-cm, 71 in.-lbf)




c. Install the No.1 engine hanger with the 2 bolts.
Torque: 20 Nm (199 kgf-cm, 14 ft-lbf)
d. Install the surge tank stay No.1 with the 2 bolts.
Torque: 20 Nm (199 kgf-cm, 14 ft-lbf)




e. Install the surge tank stay No.2 with the 2 bolts.
Torque: 20 Nm (199 kgf-cm, 14 ft-lbf)

2. INSTALL AIR CLEANER ASSEMBLY WITH HOSE
3. CONNECT VACUUM HOSE
4. INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/ FRONT SUSPENSION BRACE UPPER CENTER)
Torque: 80 Nm (816 kgf-cm, 59 ft-lbf)
5. INSTALL V-BANK COVER SUB-ASSY
6. ADD COOLANT
7. CHECK FOR COOLANT LEAKS