Intake Manifold: Service and Repair

WARNING:
- Fuel vapor Is hazardous. It can very easily Ignite, causing serious Injury and damage. Always keep sparks and flames away from fuel.
- Fuel line spills and leakage are dangers. Fuel can Ignite and cause serious Injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedures". (See Fuel Delivery and Air Induction/Service and Repair.)
- Hot engines and intake-air system can cause severe burns. Turn off the engine and wait until it and the intake-air system are cool before removing the Intake-air system.

Step 1:

1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.

Dynamic Chamber Cover Removal Note




1. Remove nuts A.
2. Remove the dynamic chamber cover in the order shown.

Air Charging Pressure Component Removal/Installation Note

NOTE: Disassemble the air charging pressure component only when its component must be replaced or serviced. After necessary service has been completed, assemble the components in the following procedure.




1. Install the mount rubber to the ABV actuator and the shutter valve body respectively.

Tightening torque: 18.6 - 25.5 N.m {1.89 - 2.61 kgf.m, 13.7 - 18.8 ft.lbf}

2. Install the shutter valve body, air intake pipe No.2, and ABV actuator to the intake manifold.
3. Tighten bolts and nuts A-F in the order.
4. Temporarily loosen bolts and nuts marked B, C, and D, then tighten them in the order.

Tightening torque: A - F: 18.6 - 25.5 N.m {1.89 - 2.61 kgf.m, 13.7 - 18.8 ft.lbf}

5. Install the air intake pipe No.1 and hand tighten bolts G.
6. Tighten nuts H, then tighten bolts G.

Tightening torque:
G1: 18.6 - 25.5 N.m {1.89 - 2.61 kgf.m, 13.7 - 18.8 ft.lbf}
G2 and H: 7.9 - 10.7 N.m {80 - 110 kgf.cm, 70 - 95 in.lbf}

Air Hose Installation Note




1. Install the clamps with their tabs facing as shown.
2. Before installing the CAC side and middle clamps, tighten the flange side of the CAC.

Step 2:

1. CAC pipe
2. Fuel hose
3. Fuel distributor connector
4. Coolant hose
5. BAC valve
6. Water pipe
7. Intake manifold component
8. Throttle body component
9. Drive belt
10. Lysholm compressor

Fuel Hose Removal Note
Before disconnecting the fuel hoses, follow the "Fuel Line Safety Procedures". (See Fuel Delivery and Air Induction/Service and Repair.)

Coolant Hose Removal Note
Before disconnecting the coolant hoses, drain the coolant from radiator.




Lysholm Compressor Installation Note
Before installation, temporarily fix the rubber onto the Lysholm compressor with two-side adhesive tape.

Intake Manifold Component Installation Note




1. Install the intake manifold component with new gaskets
2. Tighten the bolts and nuts in the order shown.

Tightening torque:
1,2,3,4: 19 - 25 N.m {1.9 - 2.6 kgf.m, 14 - 18 ft.lbf}
5,6: 20 - 30 N.m {2.0 - 3.1 kgf.m, 15 - 22 ft.lbf}