Intake Manifold: Service and Repair

Removal
1. Detach the P.C.V. hose and brake booster vacuum hose.





2. Disconnect the connecting part of vacuum hose.





3. Remove the surge tank stay.





4. After reducing the pressure of fuel pipe line to prevent fuel overflow, disconnect the connecting part of the high pressure hose.





5. Remove the surge tank stay.





6. After removing the surge tank, remove the gasket.





7. Disconnect the fuel injector harness connector.





8. Remove the delivery pipe with fuel injector and pressure regulator attached.

Caution: When removing the delivery pipe, be cautions not to drop the injectors.





9. Disconnect the wiring harness connector which is connected to the water temperature gauge unit and water temperature sensor assembly.
10. Remove the water outlet fitting and gasket.
11. Remove the thermostat.

Inspection
1. Surge tank
1) Inspect the surge tank for damage and crack, if necessary, replace it.
2) Check if cooling water passage is blocked.





3) Inspect the mating surface for warpage using a straight edge or filler gauge.
Standard value: 0.15 mm (0.006 inch)
Service limit: 0.2 mm (0.008 inch)

Installation





1. After replacing the intake manifold gasket, install the surge tank tightening the specified torque. (Standard torque: 20 - 23 Nm)
2. Install the delivery pipe and injector assembly to the intake manifold.

Caution: Check the interference between the injector and injector hole in intake manifold.





3. Install the surge tank stay.
4. Install the fuel injector connector and wiring harness.
5. Connect the high pressure fuel hose.
6. Connect the various vacuum hose.
7. Connect the PCV valve hose and brake booster hose.
8. Install the idle speed actuator.
9. Installation of thermostat
1) Install the water outlet fitting gasket which is attached to thermostat housing. Align the arrangement mark on thermostat housing with jiggle valve.
2) Smear the sealant on cooling water temperature sensor and cooling water temperature gauge unit.
10. Install the air hose.
11. Install the accelerator cable.