Intake Manifold: Service and Repair

REMOVAL
1. Disconnect battery ground cable.
2. Remove PCV hose from air intake duct.
3. Remove a nut from air intake duct bracket and loosen hose clamp on throttle body. Remove air intake duct assembly with air cleaner cover.
4. Drain engine coolant.
5. Remove water hoses from throttle body.
6. Disconnect the connector for throttle position sensor, idle air control valve sensor from throttle body.





7. Remove fuel pipe joint eye bolts from fuel rail and disconnect wire harness from fuel injector.
8. Disconnect hose from fuel pressure regulator then remove fuel rail assembly.
9. Remove throttle valve control cable from throttle body.





10. Remove fixing bolts for generator bracket.
11. Remove water pipe fixing bolt then remove water pipe.





12. Remove fixing bolt from bracket (Between cylinder block and intake manifold) of intake manifold side.
13. Remove ignition coil bracket fixing bolt.





14. Remove bolt and seven nuts, and remove intake manifold.

INSTALLATION





1. Install intake manifold with gasket to cylinder head, tighten bolt and nuts to the specified torque.

Torque: 22 Nm (16 ft. lbs.)

2. Install ignition coil bracket fixing bolt.





3. Install intake manifold bracket, tighten bolt.

Torque: 22 Nm (16 ft. lbs.)

4. Install water pipe to intake manifold.





5. Install generator bracket and tighten generator bracket bolts.

Torque
Long bolts: 35 Nm (25 ft. lbs.)
Short bolts: 20 Nm (14 ft. lbs.)

6. Install fuel rail assembly to intake manifold and connect hose between fuel pressure regulator and throttle body.





7. Install fuel pipe and tighten joint eye bolt and connect fuel injector harness.

Torque: 25 Nm (18 ft. lbs.)

8. Connect the connector for throttle position sensor and idle air control valve sensor to throttle body.
9. Install water hoses to throttle body.
10. Install intake duct assembly to throttle body and air cleaner then tighten nut to the intake duct bracket and clamp on the throttle body side and air cleaner side.

Torque: 7 Nm (5.1 ft. lbs.)

11. Install PCV hose to air intake duct.
12. Install throttle valve control cable to throttle body.
13. Confirm the free play of throttle valve control cable.

Free play: 5.7 to 6.3 mm

14. Fill engine coolant to full level from radiator filler neck.
15. Connect battery ground cable.