Intake Manifold Gasket: Service and Repair

Intake Manifold To Head Gasket No.1 Part 1:

Intake Manifold To Head Gasket No.1 Part 2:

REPLACEMENT

1. DRAIN ENGINE COOLANT
2. DISCHARGE FUEL SYSTEM PRESSURE
3. 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.

4. REMOVE V-BANK COVER

a. Remove the 2 nuts and V-bank cover.

5. REMOVE INTAKE AIR CONNECTOR PIPE

a. Disconnect the air hose and ventilation hose No. 1.
b. Loosen the 2 clamps. Then remove the bolt and intake air connector pipe.

6. REMOVE THROTTLE BODY ASSEMBLY

7. REMOVE V-BANK COVER BRACKET NO.1

a. Remove the bolt and cover bracket.

8. REMOVE V-BANK COVER BRACKET NO.2

a. Remove the bolt and cover bracket.

9. REMOVE V-BANK COVER BRACKET NO.3

a. Remove the bolt and cover bracket.

10. REMOVE V-BANK COVER BRACKET NO.4

a. Remove the 2 nuts and cover bracket.

11. REMOVE VACUUM SWITCHING VALVE ASSEMBLY

a. Disconnect the VSV connector.
b. Disconnect the 2 hoses from the VSV.
c. Remove the bolt and VSV.

12. DISCONNECT FUEL PIPE SUB-ASSEMBLY NO.2




a. Using SST, disconnect the fuel pipe.

SST 09023-38401

13. REMOVE INTAKE MANIFOLD ASSEMBLY

a. Remove the installation bolts and the water by-pass pipe No. 1 and No. 2.
b. Disconnect the vacuum hose of the brake booster.
c. Disconnect the air hose of the power steering.
d. Disconnect the ventilation hose.
e. Disconnect the 8 injector connectors.
f. Remove the 6 bolts, 4 nuts and intake manifold.

14. REMOVE INTAKE MANIFOLD TO HEAD GASKET NO.1

15. INSTALL INTAKE MANIFOLD TO HEAD GASKET NO.1




a. Install 2 new gaskets to the cylinder head as shown in the illustration.

HINT: The side of the gasket with white paint should point outward.

16. INSTALL INTAKE MANIFOLD ASSEMBLY

a. Install the intake manifold with the 6 bolts and 4 nuts.

Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)

b. Connect the 8 injector connectors.
c. Disconnect the ventilation hose.
d. Connect the air hose for the power steering.
e. Connect the vacuum hose for the brake booster.
f. Install the water by-pass pipe No. 1 and No. 2 with the bolt.

17. INSTALL FUEL PIPE SUB-ASSEMBLY NO.2




a. Using SST, install the fuel pipe.

SST 09023-38401

Torque: 35 N.m (357 kgf.cm, 26 ft.lbf) 28 N.m (286 kgf.cm, 21 ft.lbf) for use with SST

HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

18. INSTALL VACUUM SWITCHING VALVE ASSEMBLY

a. Install the VSV with the bolt.

Torque: 7.5 N.m (76 kgf.cm, 66 im.lbf)

19. INSTALL V-BANK COVER BRACKET NO.4

a. Install the cover bracket with the 2 nuts.

Torque: 7.5 N.m (76 kgf.cm, 66 im.lbf)

20. INSTALL V-BANK COVER BRACKET NO.3

a. Install the cover bracket with the bolt.

Torque: 7.5 N.m (76 kgf.cm, 66 im.lbf)

21. INSTALL V-BANK COVER BRACKET NO.2

a. Install the cover bracket with the bolt.

Torque: 7.5 N.m (76 kgf.cm, 66 im.lbf)

22. INSTALL V-BANK COVER BRACKET NO.1

a. Install the cover bracket with the bolt.

Torque: 7.5 N.m (76 kgf.cm, 66 im.lbf)

23. INSTALL THROTTLE BODY ASSEMBLY

24. INSTALL INTAKE AIR CONNECTOR PIPE

a. Install the intake air connector pipe with the bolt and hose clamp.

Torque: 4.0 N.m (41 kgf.cm, 35 im.lbf) for hose clamp 5.0 N.m (51 kgf.cm, 44 im.lbf) for bolt

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

25. CHECK FOR FUEL LEAKS
26. INSTALL V-BANK COVER

a. Install the V-bank cover with the 2 nuts.

Torque: 5.0 N.m (51 kgf.cm, 44 im.lbf)

27. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
28. PERFORM INITIALIZATION

NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.

29. ADD ENGINE COOLANT
30. CHECK FOR ENGINE COOLANT LEAKS