Intake Manifold: Service and Repair

Intake Manifold To Head Gasket No.1:

INTAKE MANIFOLD TO HEAD GASKET NO.1

REPLACEMENT

1. DRAIN ENGINE COOLANT
2. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT
3. REMOVE V-BANK COVER [11259]
a. Remove the V-bank cover by removing the 2 nuts.

4. REMOVE INTAKE AIR CONNECTOR PIPE [17875]
a. Disconnect the air hose and ventilation hose No.1.
b. Remove the intake air connector pipe by removing the bolt and hose clamp.

5. REMOVE THROTTLE BODY ASSY [22210]
6. REMOVE V-BANK COVER BRACKET NO.1 [11254]
7. REMOVE V-BANK COVER BRACKET NO.2 [11256]
8. REMOVE V-BANK COVER BRACKET NO.3 [11257]
9. REMOVE V-BANK COVER FASTENER [11258A]
10. REMOVE VACUUM SWITCHING VALVE ASSY [17650]
11. SEPARATE FUEL PIPE SUB-ASSY NO.2 [23802B]




a. Using a union nut wrench 14, disconnect the fuel main hose.

SST 09023 - 38400

12. REMOVE INTAKE MANIFOLD ASSY
a. Remove the installation bolts and the water bypass pipes No.1 and No.2.
b. Disconnect the vacuum hose (for the brake booster).
c. Disconnect the air hose (of the power steering).
d. Disconnect the ventilation hose.
e. Disconnect the connector (for the injector).
f. Remove the intake manifold by taking off the 6 bolts and 4 nuts.

13. REMOVE INTAKE MANIFOLD TO HEAD GASKET NO.1 [17177]
14. INSTALL INTAKE MANIFOLD TO HEAD GASKET NO.1 [17177]




a. Install a new gasket to the cylinder head, as shown in the illustration.

NOTE: Face the white painted side upward.

15. INSTALL INTAKE MANIFOLD ASSY
a. Install the intake manifold with the 6 bolts and 4 nuts.
b. Connect the connector (for the injector).
c. Disconnect the ventilator hose.
d. Connect the air hose (for the power steering).
e. Connect the vacuum hose (for the brake booster).
f. Install the water bypass pipes No.1 and No.2 with the bolt.

16. INSTALL FUEL PIPE SUB-ASSY NO.2 [23802B]




a. Using a union nut wrench 14, install the fuel main hose.

Torque: 35 N.m (355 kgf.cm, 26 in.lbf)

SST 09023 - 38400

17. INSTALL VACUUM SWITCHING VALVE ASSY [17650]

Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf)

18. INSTALL V-BANK COVER FASTENER [11258A]

Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf)

19. INSTALL V-BANK COVER BRACKET NO.3 [11257]

Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf)

20. INSTALL V-BANK COVER BRACKET NO.2 [11256]

Torque: 7.5 N.m (80 kgf.cm, 66 in..lbf)

21. INSTALL V-BANK COVER BRACKET NO.1 [11254]

Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf)

22. INSTALL INTAKE AIR CONNECTOR PIPE [17875]
a. Install the intake air connector pipe with the bolt and the hose clamp.

Torque:
4 N.m (40 kgf.cm, 35 in.lbf) for hose clamp
5 N.m (50 kgf.cm, 44 in.lbf) for bolt

b. Connect the air hose and the ventilation hose No.1 together.

23. INSPECT FUEL PUMP OPERATION AND CHECK FOR FUEL LEAKS
24. INSTALL V-BANK COVER [11259]

Torque: 5 N.m (50 kgf.cm, 44 in.lbf)

25. REFILL ENGINE COOLANT
26. INSPECT CHECK ENGINE COOLANT LEAK