Intake Manifold: Service and Repair
REMOVAL1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
3. DRAIN ENGINE COOLANT
4. REMOVE V-BANK COVER ASSEMBLY
a. Remove the 2 nuts and cover.
5. REMOVE COOL AIR INTAKE DUCT SEAL
6. REMOVE AIR CLEANER INLET
a. Remove the bolt and inlet.
7. REMOVE ENGINE ROOM SIDE COVER RH
8. REMOVE ENGINE ROOM SIDE COVER LH
9. REMOVE INTAKE AIR CONNECTOR PIPE
10. REMOVE THROTTLE BODY ASSEMBLY
11. REMOVE NO. 4 V-BANK COVER BRACKET
a. Disconnect the connector as shown in A in the illustration.
b. Remove the bolt and bracket.
12. REMOVE V-BANK COVER BRACKET
a. Remove the bolt and bracket as shown in B in the illustration.
13. REMOVE VACUUM SWITCHING VALVE ASSEMBLY (for EVAP)
a. Disconnect the connector from the VSV, as shown in C in the illustration.
b. Disconnect the vacuum hose from the VSV, as shown in C in the illustration.
c. Remove the bolt and VSV as shown in C in the illustration.
14. REMOVE NO. 2 V-BANK COVER BRACKET
a. Remove the bolt and bracket from the intake manifold, as shown in D in the illustration.
15. REMOVE NO. 3 V-BANK COVER BRACKET
a. Disconnect the connector as shown in E in the illustration.
b. Remove the bolt and bracket as shown in E in the illustration.
16. DISCONNECT ENGINE WIRE
a. Remove the 3 bolts and disconnect the engine wire protector (LH side) from the intake manifold upper and camshaft bearing cap.
b. Disconnect the 2 wire clamps on the engine wire (RH side) from the brackets on the RH delivery pipe.
c. Remove the 2 bolts and disconnect the engine wire protector (rear side) from the rear water by-pass joint and RH cylinder head.
17. DISCONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY
18. REMOVE INTAKE MANIFOLD SUB-ASSEMBLY
a. Disconnect the 8 injector connectors.
b. Remove the 6 bolts, 4 nuts, intake manifold and 2 gaskets.
DISASSEMBLY
1. REMOVE VACUUM CONTROL VALVE SET
a. Disconnect the vacuum hose from the intake air control valve actuator.
b. Disconnect the VSV connector.
c. Disconnect the 2 vacuum hoses from the manifold and clamp.
d. Remove the bolt and harness clamp.
e. Remove the 2 nuts and vacuum control valve set.
2. REMOVE INTAKE AIR CONTROL VALVE ACTUATOR
a. Remove the 3 nuts, actuator and gasket.
3. REMOVE INTAKE MANIFOLD SUB-ASSEMBLY UPPER
a. Remove the 14 bolts, 6 nuts, manifold upper and gasket from the manifold lower.
4. REMOVE INTAKE AIR CONTROL VALVE ASSEMBLY
a. Remove the 6 bolts and control valve.
5. REMOVE VACUUM SWITCHING VALVE ASSEMBLY (for ACIS)
a. Remove the screw and VSV from the vacuum tank.
REASSEMBLY
1. INSTALL VACUUM SWITCHING VALVE ASSEMBLY (for ACIS)
a. Install the VSV to the vacuum tank with the screw.
Torque: 1.4 N.m (14 kgf.cm, 12 in.lbf)
2. INSTALL INTAKE AIR CONTROL VALVE ASSEMBLY
a. Install the valve with the 6 bolts.
Torque: 8.5 N.m (87 kgf.cm, 75 in.lbf)
3. INSTALL INTAKE MANIFOLD SUB-ASSEMBLY UPPER
a. Install a new gasket and the manifold upper to the manifold lower with the 14 bolts and 6 nuts.
Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)
4. INSTALL INTAKE AIR CONTROL VALVE ACTUATOR
HINT: Before installing the actuator, adjust the intake air control valve to the fully closed position.
a. Install a new gasket and the actuator with the 3 nuts.
Torque: 8.5 N.m (87 kgf.cm, 75 in.lbf)
5. INSTALL VACUUM CONTROL VALVE SET
a. Install the vacuum control valve set with the 2 nuts.
Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)
b. Connect the 2 vacuum hoses to the manifold and clamp.
c. Connect the VSV connector.
d. Install the harness clamp to the manifold with the bolt.
Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf)
e. Connect the vacuum hose to the air control valve actuator.
INSTALLATION
1. INSTALL INTAKE MANIFOLD SUB-ASSEMBLY UPPER
a. Set 2 new gaskets on the cylinder head.
HINT: Make sure the white paint marks are facing upward.
b. Install the intake manifold to the gasket and cylinder head with the 6 bolts and 4 nuts.
Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)
c. Connect the 8 injector connectors.
2. CONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY
a. Connect the No. 2 fuel pipe.
3. CONNECT ENGINE WIRE
a. Install the wire protector (LH side) with the 3 bolts.
b. Install the 2 wire clamps on the engine wire (RH side) to the brackets on the RH delivery pipe.
c. Install the engine wire protector (rear side) to the rear water by-pass joint and RH cylinder head with the 2 bolts.
4. INSTALL NO. 3 V-BANK COVER BRACKET
a. Install the bracket to the manifold with the bolt, as shown in E in the illustration.
Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf)
b. Connect the connector as shown in E in the illustration.
5. INSTALL NO. 2 V-BANK COVER BRACKET
a. Install the bracket to the manifold with the bolt, as shown in D in the illustration.
Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf)
6. INSTALL VACUUM SWITCHING VALVE ASSEMBLY (for EVAP)
a. Install the bracket of the VSV to the manifold with the bolt, as shown in C in the illustration.
Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)
b. Connect the vacuum hose to the VSV, as shown in C in the illustration.
c. Connect the connector to the VSV, as shown in C in the illustration.
7. INSTALL V-BANK COVER BRACKET
a. Install the bracket to the manifold with the bolt, as shown in the illustration B.
Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf)
8. INSTALL NO. 4 V-BANK COVER BRACKET
a. Install the bracket to the manifold with the 2 nuts, as shown in the illustration A.
Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)
9. INSTALL THROTTLE BODY ASSEMBLY
10. INSTALL INTAKE AIR CONNECTOR PIPE
11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
12. CHECK FOR FUEL LEAKS
a. Check for fuel leaks.
13. ADD ENGINE COOLANT
14. CHECK FOR COOLANT LEAKS
a. Check for engine coolant leaks.
15. INSTALL V-BANK COVER SUB-ASSEMBLY
a. Install the cover with the 2 nuts.
Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)
16. INSTALL ENGINE ROOM SIDE COVER LH
17. INSTALL ENGINE ROOM SIDE COVER RH
18. INSTALL AIR CLEANER INLET
a. Install the inlet with the bolt.
Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)
19. INSTALL COOL AIR INTAKE DUCT SEAL
20. PERFORM INITIALIZATION
a. Perform initialization.
NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.