Intake Manifold: Service and Repair

<2.0L ENGINE (NON-TURBO)>









Removal
Pre-removal Operation:
- Residual Fuel Pressure Releasing.
- Engine Coolant Draining.
- Reservoir Assembly Removal

Follow removal steps outlined in illustration.

Removal Service Points
[A] High-pressure Fuel Hose Disconnection.
Relieve pressure in the fuel pipe line to prevent fuel outflow.

CAUTION: Cover fuel pipe line with shop towel after relieving pressure as certain pressure may still remain.

[B] Fuel Rail, Fuel Injector And Pressure Regulator Assembly Removal.
Remove fuel rail with fuel injector and pressure regulator on.

CAUTION: Do not drop fuel injector when removing fuel rail.

Inspection
Check the following points. Replace the part if a problem is found.

Intake Manifold Check
1. Check for damage or cracking of any part.
2. Check for obstruction of the negative pressure (vacuum) outlet port, and For obstruction of the water passage or gas passage.
Using a straight edge and a feeler gauge, check for distortion of the cylinder head installation surface.

Standard value: 0.15 mm (0.006 inch) or less.
Limit: 0.2 mm (0.008 inch)

Installation
Installation in reverse order as removal.

Installation Service Points

]A[ Fuel Rail, Fuel Injector And Pressure Regulator Assembly Installation.
Apply a small amount of new engine oil to the O-ring.

]B[ High-pressure Fuel Hose Connection.
When connecting the high-pressure fuel hose to the fuel rail, apply a small amount of new engine oil to the hose union, and then insert, being careful not to damage the O-ring.

CAUTION: Do not let engine oil get into the fuel rail.

Post-installation Operation:
- Reservoir Assembly Installation.
- Engine Coolant Supplying.
- Accelerator Cable Adjustment.

<2.0L ENGINE (TURBO)>

Removal
Pre-removal Operation:
- Residual Fuel Pressure Releasing.
- Engine Coolant Draining.
- Battery Removal.

Follow removal steps outlined in illustration.

Removal Service Points
[A] High-pressure Fuel Hose Disconnection.
Relieve pressure in the fuel pipe line to prevent fuel outflow.

CAUTION: Cover fuel pipe line with shop towel after relieving pressure as certain pressure may still remain.

[B] Fuel Rail, Fuel Injector And Pressure Regulator Assembly Removal.
Remove fuel rail with fuel injector and pressure regulator attached.

CAUTION: Do not drop fuel injector when removing fuel rail.

Inspection
Check the following points. Replace the part if a problem is found.

Intake Manifold Check
1. Check for damage or cracking of any part.
2. Check for obstruction of the negative pressure (vacuum) outlet port, and for obstruction of the water passage or gas passage.
3. Using a straight edge and a feeler gauge, check for distortion of the cylinder head installation surface.

Standard value: 0.15 mm (0.006 inch) or less
Limit: 0.2 mm (0.008 inch)

Installation
Installation in reverse order as removal.

Installation Service Point
]A[ High-pressure Fuel Hose Connection.
When connecting the high-pressure fuel hose to the fuel rail, apply a small amount of new engine oil to the hose union, and then insert, being careful not to damage the O-ring.

CAUTION: Do not let engine oil get into the fuel rail.

Post-installation Operation:
- Battery Installation.
- Engine Coolant Supplying.
- Accelerator Cable Adjustment.

<2.4L ENGINE>

Removal
Pre-removal Operation:
- Residual Fuel Pressure Releasing.
- Engine Coolant Draining.
- Battery Removal.

Follow removal steps outlined in illustration.

Removal Service Points
[A] High-pressure Fuel Hose Disconnection.
Relieve pressure in the fuel pipe line to prevent fuel outflow.

CAUTION: Cover fuel pipe line with shop towel after relieving pressure as certain pressure may still remain.

[B] Fuel Rail, Fuel Injector And Pressure Regulator Assembly Removal.
Remove fuel rail with fuel injector and pressure regulator attached.

CAUTION: Do not drop fuel injector when removing fuel rail.

Inspection
Check the following points. Replace the part if a problem is found.

Intake Manifold Check
1. Check for damage or cracking of any part.
2. Check for obstruction of the negative pressure (vacuum) outlet port, and or obstruction of the water passage or gas passage.
Using a straight edge and a feeler gauge, check for distortion of the cylinder head installation surface.

Standard value: 0.15 mm (0.006 inch) or less
Limit: 0.2 mm (0.008 inch)

Installation
Installation in reverse order as removal.

Installation Service Point
]A[ High-pressure Fuel Hose Connection.
When connecting the high-pressure fuel hose to the fuel rail, apply a small amount of new engine oil to the hose union, and then insert, being careful not to damage the O-ring.

CAUTION: Do not let engine oil get into the fuel rail.

Post-installation Operation:
- Battery Installation.
- Engine Coolant Supplying.
- Accelerator Cable Adjustment.