Overhaul

Intake Manifold

DISASSEMBLY

1. Remove the intake manifold protector RH from intake manifold.






2. Disconnect front oxygen (A/F) sensor connector (A) and rear oxygen sensor connector (B) from the intake manifold protector LH, and also remove clip (C) which holds the engine harness.






3. Remove the engine ground terminal from the intake manifold protector LH, and remove the intake manifold protector LH from the intake manifold.






4. Remove the filter assembly.






5. Disconnect the vacuum hose from the intake manifold and fuel delivery pipe.






6. Disconnect the connector from the manifold absolute pressure sensor, and remove the solenoid valve bracket assembly from the intake manifold.






7. Disconnect the connectors from the purge control solenoid valves 1 and 2.






8. Disconnect the connectors from the throttle position sensor.






9. Remove the throttle body from the intake manifold.






10. Disconnect the connector from the fuel injector and tumble generator valve assembly.






11. Remove the brake booster vacuum hose from the clip (A), and remove PCV pipe (B) and engine harness (C) from the intake manifold.






12. Remove the bolts which secure the fuel delivery pipe assembly to the intake manifold, and disconnect the pressure regulator vacuum hose from the intake manifold.






13. Remove the bolts which hold fuel pipe onto intake manifold.






14. Remove the fuel injector.






15. Disconnect vacuum hose (A), vacuum control hose (B) and brake booster vacuum hose (C) from the intake manifold.






16. Remove the bolts which secure the fuel delivery pipe to the intake manifold, loosen the clamps which hold the fuel hose to the fuel delivery pipe, and remove the fuel delivery pipe and fuel pipe.






17. Remove the nipple from the intake manifold.






18. Remove the tumble generator valve assembly from the intake manifold.






ASSEMBLY

1. Install the tumble generator valve assembly onto intake manifold.

NOTE: Use new O-rings.

Tightening torque: 8.3 N.m (0.8 kgf.m, 6.1 ft.lb)






2. Apply liquid gasket to the nipple threads, and install the nipple to the intake manifold.

Liquid gasket:
THREE BOND 1105 (Part No. 004403010) or equivalent

Tightening torque: 23 N.m (2.3 kgf.m, 17.0 ft.lb)






3. Set the fuel delivery pipe and fuel pipe, tighten the clamps which hold the fuel hose to the fuel delivery pipe, and install the fuel delivery pipe to the intake manifold.

Tightening torque:
T1: 1.25 N.m (0.1 kgf.m, 0.9 ft.lb)
T2: 6.4 N.m (0.7 kgf.m, 4.7 ft.lb)






4. Connect vacuum hose (A), vacuum control hose (B) and brake booster vacuum hose (C) to the intake manifold.






5. Install the fuel injector.






6. Install the bolts which secure fuel pipe to the intake manifold.

Tightening torque: 19 N.m (1.9 kgf.m, 14.0 ft.lb)






7. Install the bolts which secure fuel delivery pipe to the intake manifold, and connect the pressure regulator vacuum hose to the intake manifold.

Tightening torque: 6.4 N.m (0.7 kgf.m, 4.7 ft.lb)






8. Install PCV pipe (B) and engine harness (C) to the intake manifold, and install the brake booster vacuum hose to the clip (A).

Tightening torque: 6.4 N.m (0.7 kgf.m, 4.7 ft.lb)






9. Connect the connector to the fuel injector and the tumble generator valve assembly.






10. Install the throttle body to the intake manifold.

NOTE: Use new O-rings.

Tightening torque: 8 N.m (0.8 kgf.m, 5.9 ft.lb)






11. Connect the connector to the throttle position sensor.






12. Connect the connectors to the purge control solenoid valves 1 and 2.






13. Install the solenoid valve bracket assembly to the intake manifold, and connect the connector to the manifold absolute pressure sensor.

Tightening torque: 19 N.m (1.9 kgf.m, 14.0 ft.lb)






14. Connect the vacuum hose to the intake manifold and fuel delivery pipe.






15. Install the filter assembly.






16. Install the intake manifold protector LH to the intake manifold, and install the engine ground terminal to the intake manifold protector.

NOTE: Route the from front oxygen (A/F) sensor connector and rear oxygen sensor connector inside the intake manifold protector, as shown in the figure.






Tightening torque: 19 N.m (1.9 kgf.m, 14.0 ft.lb)






17. Install front oxygen (A/F) sensor connector (A) and rear oxygen sensor connector (B) to the intake manifold protector LH, and also install clip (C) which holds the engine harness.






18. Install the intake manifold protector RH to the intake manifold.

Tightening torque: 19 N.m (1.9 kgf.m, 14.0 ft.lb)