Intake Manifold: Service and Repair
REMOVAL
1. Release fuel pressure.
2. Open fuel flap lid, and remove fuel filler cap.
3. Disconnect the battery ground cable.
4. Remove the air intake duct, air cleaner assembly and air intake chamber.
5. Disconnect accelerator cable (A).
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6. Disconnect the cruise control cable (B). (if equipped)
7. Remove the power steering pump and tank from brackets.
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(1) Remove the resonator chamber.
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(2) Remove V-belt covers.
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(3) Loosen the lock bolt and slider bolt, and remove the power steering pump drive V-belt.
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(4) Remove the bolts that hold the power steering pipes onto the intake manifold protector.
NOTE: Do not disconnect the power steering hose.
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(5) Remove the bolts that install the power steering pump bracket.
(6) Disconnect connector from power steering pump switch.
(7) Remove the power steering tank from the bracket by pulling it upward.
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(8) Place the power steering pump on the right side wheel apron.
8. Disconnect the spark plug wires from spark plugs.
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9. Disconnect the PCV hose from the intake manifold.
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10. Disconnect the engine coolant hose from the throttle body.
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11. Disconnect the brake booster hose.
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12. Remove the air cleaner case stay RH and the engine harness bracket, and disconnect the engine harness connectors from the bulkhead harness connectors.
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13. Disconnect the connectors from the engine coolant temperature sensor.
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14. Disconnect the knock sensor connector.
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15. Disconnect the connector from the crankshaft position sensor.
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16. Disconnect the connector from the oil pressure switch.
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17. Disconnect the connector from the camshaft position sensor.
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18. Disconnect the fuel hoses from the fuel pipes.
(A) Fuel delivery hose
(B) Return hose
(C) Evaporation hose
Warning:
- Do not spill fuel.
- Catch fuel from hoses in a container or cloth.
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19. remove the bolts that hold the intake manifold onto the cylinder heads.
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Remove the intake manifold.
INSTALLATION
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1. Install the intake manifold onto the cylinder heads.
CAUTION: Always use new gaskets.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
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2. Connect fuel hoses.
(A) Fuel delivery hose
(B) Return hose
(C) Evaporation hose
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3. Connect the connector to the camshaft position sensor.
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4. Connect the connector to the oil pressure switch.
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5. Connect the connector to the crankshaft position sensor.
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6. Connect the knock sensor connector.
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7. Connect the connectors for the engine coolant temperature sensor.
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8. Install the air cleaner case stay RH and the engine harness bracket, and connect the engine harness connectors to the bulkhead connectors.
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9. Connect the brake booster hose.
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10. Connect the engine coolant hose to the throttle body.
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11. Connect the PCV hose to the intake manifold.
12. Connect the spark plug wires to the spark plugs.
13. Install the power steering pump and tank on brackets.
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(1) Install the power steering tank on bracket.
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(2) Connect the connector to the power steering pump switch.
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(3) Tighten the bolts that hold the power steering pump to the bracket.
Tightening torque:
10.1 Nm (2.05 kgf=m, 14.8 ft-lb)
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(4) Install the power steering pipes onto the right side intake manifold protector.
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(5) Install the power steering pump drive V-belt.
(6) Adjust V-belt.
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(7) Install the V-belt covers.
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(8) Install the resonator chamber.
Tightening torque: 33 Nm (3.4 kgf-m, 24.6 ft-lb)
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14. Connect the accelerator cable (A).
15. Connect the cruise control cable (B) (if equipped).
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16. Install the air intake duct and air cleaner assembly.
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17. Connect the connector to the fuel pump relay.
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18. Connect the battery ground cable.