Intake Manifold: Service and Repair

AIR INTAKE SURGE TANK
REMOVAL

1. Remove the air intake hose connected to the throttle body.

2. Remove the accelerator and cruise control cables.
3. Remove the engine coolant hose.

4. Remove the P.C.V. hose and brake booster vacuum hoses.
5. Disconnect the vacuum hose connections.
6. Remove the ISA, TIPS and ATS connector.
7. Remove the surge tank stay.
8. Remove the air intake surge tank and surge tank gasket.

INSPECTION
1. Check the intake surge tank for defect or cracks. Replace if defective.
2. Check coolant passage ways for restrictions. Clean if necessary.

3. Check deflection of installation surface with straight edge and feeler gauge.
Standard value: Within 0.15 mm (0.006 inch)
Service limit: 0.2 mm (0.008 inch)

INSTALLATION

1. Install the surge tank and throttle body according to the reverse order of removal.

CAUTION: Do not use the used surge tank gasket.

INTAKE MANIFOLD
REMOVAL
1. Remove the air intake surge tank.
2. Remove the high pressure fuel hose.

CAUTION: Reduce the internal pressure of the high pressure fuel hose prior to disconnecting. For more details, refer to Powertrain Management; Fuel Delivery and Air Induction.

3. Disconnect the fuel return hose.

4. Remove the delivery pipe with the fuel injector.

NOTE: Be careful not to drop the injector when removing the delivery pipe.

CAUTION: Be aware that fuel may flow out when removing the injector.

4. Remove the intake manifold and gasket.

INSPECTION
Intake Manifold
1. Check the intake manifold for damage, cracking, or restriction of the vacuum outlet port, water and or gas passages.

2. Check for distortion of the cylinder head mounting surface and surge tank mounting surface by using a straight edge and feeler gauge.
Standard value: 0.15 mm (0.006 inch) or less
Service limit value: 0.2 mm (0.0078 inch)

INSTALLATION
1. Install the intake manifold and delivery pipe according to the reverse order of removal.

CAUTION: Do not use the used intake manifold gasket.