Removal and Installation

INTAKE MANIFOLD


Removal and Installation


REMOVAL

WARNING:
To avoid the danger of being scalded, never drain the engine coolant when the engine is hot.
1. Remove engine room cover (RH and LH). Refer to Component Removal and Installation.
2. Remove engine cover with power tool.





3. Release fuel pressure. Refer to Testing and Inspection.
4. Remove air duct (inlet), air cleaner case, and air duct and resonator assembly. Refer to Exploded View Removal and Installation.
5. Drain engine coolant from radiator. Refer to Changing Engine Coolant.

CAUTION:
- Perform this step when the engine is cold.
- Never spill engine coolant on drive belts.





6. Disconnect fuel feed hose quick connector (1) on engine side. Refer to Component Removal and Installation.
7. Remove fuel damper and fuel hose assembly. Refer to Component Removal and Installation.

CAUTION:
- While hoses are disconnected, plug them to prevent fuel from draining.
- Never separate fuel damper and fuel hose.
8. Remove or disconnect harnesses, engine cover bracket (RH and LH), vacuum hose, EVAP tube and hose and PCV hose and tube from intake manifold (upper).





9. Loosen mounting bolts in reverse order as shown in the figure to remove intake manifold (upper) with power tool.

10. Remove electric throttle control actuator as follows:
a. Disconnect harness connector.
b. Loosen mounting bolts diagonally.

CAUTION:
- Handle carefully to avoid any shock to electric throttle control actuator.
- Never disassemble.
11. Remove fuel injector and fuel tube assembly. Refer to Component Removal and Installation.
12. Disconnect water hoses from intake manifold adaptor.





13. Loosen mounting bolts in reverse order as shown in the figure to remove intake manifold (lower) with power tool.

14. Remove intake manifold adaptor from intake manifold (lower).
15. Remove vacuum tank.
16. Remove intake manifold gaskets.

CAUTION:
Cover engine openings to avoid entry of foreign materials.

INSPECTION AFTER REMOVAL

Surface Distortion
- Check the surface distortion of both the intake manifold (upper and lower) mating surfaces with straightedge and feeler gauge.






Limit : 0.1 mm (0.004 in)

- If it exceeds the limit, replace intake manifolds (lower and/or upper).

INSTALLATION
Note the following, and install in the reverse order of removal.

Intake Manifold (Lower)
Tighten in numerical order as shown in the figure.






- There are two types of mounting bolts. Refer to the following for locating bolts.

M8 � 90 mm (3.54 in) : 7, 8
M8 � 35 mm (1.38 in) : Except the above


Intake Manifold (Upper)
Tighten in numerical order as shown in the figure.





Electric Throttle Control Actuator
- Install gasket with its directional protrusion set up/downward.
- Tighten mounting bolts of electric throttle control actuator equally and diagonally in several steps.
- After installation perform procedure in "INSPECTION AFTER INSTALLATION".

Water Hose
Insert hose by 27 to 32 mm (1.06 to 1.26 in) from connector end.

Vacuum Hose
Refer to [1][2]Diagrams.

INSPECTION AFTER INSTALLATION
- Perform the "Throttle Valve Closed Position Learning" when harness connector of electric throttle control actuator is disconnected. Refer to Throttle Valve Closed Position Learning.
- Perform the "Idle Air Volume Learning" and "Throttle Valve Closed Position Learning" when electric throttle control actuator is replaced. Refer to Testing and Inspection.