Intake Manifold: Service and Repair

REMOVAL AND INSTALLATION

Intake Manifold:

REMOVAL SERVICE POINT

[[A]] FUEL RAIL, INJECTOR AND FUEL PRESSURE REGULATOR REMOVAL

CAUTION: Care must be taken when removing the fuel rail not to drop the injector.

Remove the fuel rail with the injectors and pressure regulator attached to it.

INSTALLATION SERVICE POINTS

]]A[[ INTAKE MANIFOLD GASKET INSTALLATION




Install the gasket with the protrusions in the position illustrated.

]]B[[ INTAKE MANIFOLD INSTALLATION
1. Coat the intake manifold mounting studs with engine oil.







2. Tighten the intake manifold mounting nuts by the following procedure.

]]C[[ HIGH-PRESSURE FUEL HOSE INSTALLATION

CAUTION: Be careful not to allow any engine oil to enter the fuel rail.




1. When connecting the high-pressure fuel hose to the fuel rail, apply a small amount of new engine oil to the O-ring and then insert the high-pressure fuel hose, being careful not to damage the O-ring.
2. While turning the high-pressure fuel hose to the left and right, install it to the fuel rail.
3. Check that the injector turns smoothly. If it does not turn smoothly, the O-ring may be trapped. Remove the high-pressure fuel hose and then re-insert it into the fuel rail and check again.

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 feeler gauge, check for distortion of the cylinder head installation surface.

Standard value: 0.15 mm (0.006 inch) or less

Limit: 0.20 mm (0.008 inch)