Intake Manifold: Service and Repair

REMOVAL






1. Remove Vacuum Switching Valve (VSV) for fuel pressure control, disconnect the following connector and hoses:






(a) VSV connector (1).
(b) Vacuum sensing hose (2) from fuel pressure regulator.
(c) Vacuum sensing hose (3) from air intake chamber.






2. On models with Automatic Transmission (A/T), remove the oil dipstick bolt, then pull out the dipstick guide together with the dipstick.
- Remove the O-ring from the dipstick guide.






3. On all models, remove oil dipstick and guide for engine as follows:
(a) Disconnect the fuel return hose from the clamp of the dipstick guide.
(b) Remove the bolt.
(c) Pull out the dipstick guide together with the dipstick.
(d) Remove the O-ring from the dipstick guide.






4. Loosen the union nut of the EGR pipe, then Remove EGR pipe.






5. Disconnect EGR gas temperature sensor connector as follows:
(a) Disconnect the connector from the No.2 vacuum pipe.
(b) Disconnect the sensor connector from the wiring connector.
6. Disconnect No.2 vacuum pipe and VSV assembly.
7. Remove air intake chamber as follows:






(a) Remove the 2 nuts holding the throttle body bracket to the cylinder head.






(b) Remove the 4 bolts and 2 nuts holding the intake air connector to the air intake chamber.
(c) Remove the bolt, and disconnect the engine wire protector from the air intake chamber.
(d) Disconnect these hoses:






- 3 vacuum hoses (1) from No.2 vacuum pipe and from No.1 vacuum pipe.
- Vacuum hose (2) from No.2 vacuum pipe and from a intake chamber.






- Power Steering (PS) air hose (3) from air intake chamber.
- Brake booster vacuum hose (4) from air intake chamber.
Remove the union bolt and 2 gaskets, and disconnect the vacuum hose.
- Vacuum hose (5) from actuator for Acoustic Control Induction System (ACIS) and from No. 1 vacuum pipe.






(e) Loosen the 2 nuts holding the air intake chamber stays to the cylinder head.
(f) Remove the 2 bolts, and disconnect the 2 air intake chamber stays from the air intake chamber.






(g) Remove the 5 bolts, nut, air intake chamber and 2 gaskets.
8. Remove the fuel injectors, refer to Powertrain Management.
9. Remove the intake manifold mounting nuts, then the manifold and gaskets.

INSTALLATION
Installation is the reverse of removal, noting the following information.
(a) Mount intake manifold with new gaskets, tighten nuts to 39 Nm (400kg. cm., 29 ft. lbs.).






(b) Install a new gasket to the air intake chamber, facing the protrusion rearward, tighten bolts to 27 Nm (280 kg. cm., 20 ft. lbs.).
(c) Tighten intake chamber stays to 18 Nm (185 kg. cm, 13 ft. lbs.).
(d) Tighten brake booster union bolt to 29 Nm (300 kg. cm, 22 ft. lbs.).
(e) Tighten the 4 bolts and 2 nuts holding the intake air connector to the air intake chamber to: 27 Nm (280 kg. cm., 20 ft. lbs.).
(f) Tighten the two No.2 vacuum pipe and VSV assembly nuts to: 27 Nm (280 kg. cm, 20 ft. lbs.).
(g) Tighten the the union nut of the EGR pipe to: 64 Nm (650 kg. cm., 47 ft. lbs.).
(h) Tighten the two EGR pipe bolts to: 27 Nm (280 kg. cm., 20 ft. lbs.).
(i) Tighten the 2 nuts holding the throttle body bracket to the cylinder head to: 21 Nm (210 kg. cm., 15 ft. lbs.).
(j) When installing dipsticks:
- Use a new O-ring.
- Apply soapy water to the O-ring, and push in the dipstick guide.