INTAKE MANIFOLD REMOVAL/INSTALLATION [13B-MSP]

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Warning

•  Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.

•  Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can ignite and cause serious injury or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedure” while referring to the “BEFORE SERVICE PRECAUTION”.

•  Remove the engine, transmission and crossmember carefully, holding it steady. If the transmission falls it could be damaged or cause injury.

•  After disconnecting the steering shaft joint, always set the EPS system to the neutral position to prevent system malfunction. (See EPS SYSTEM NEUTRAL POSITION SETTING.)

Caution

•  Do not bend the jet air fuel mixing nozzle. Otherwise malfunction of the engine may occur. Exercise extreme caution when handling the intake manifold.

Note

•  The engine must be removed to remove the intake manifold.

•  Remove the engine, transmission, and crossmember component as a single unit downward of the vehicle.

1.  Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [13B-MSP].)

2.  Remove the following parts:

(1)  Front wheel and tires (SeeGENERAL PROCEDURES (SUSPENSION).)

(2)  Engine cover (SeeENGINE COVER REMOVAL/INSTALLATION [13B-MSP].)

(3)  Front suspension tower bar (SeeFRONT SUSPENSION TOWER BAR REMOVAL/INSTALLATION [MT].)(See FRONT SUSPENSION TOWER BAR REMOVAL/INSTALLATION [AT].)

(4)  Battery cover, battery, battery box and battery tray (SeeBATTERY REMOVAL/INSTALLATION [13B-MSP].)

(5)  Air cleaner, intake-air duct and air cleaner insulator (SeeINTAKE-AIR SYSTEM REMOVAL/INSTALLATION [13B-MSP].)

(6)  PCM connector (See PCM REMOVAL/INSTALLATION [13B-MSP].)

(7)  AIR pump (See SECONDARY AIR INJECTION (AIR) PUMP REMOVAL/INSTALLATION [13B-MSP].)

3.  Drain the engine coolant. (SeeENGINE COOLANT REPLACEMENT [13B-MSP].)

4.  Disconnect the brake vacuum hose. (See POWER BRAKE UNIT REMOVAL/INSTALLATION.)

5.  Disconnect the fuel hose from the fuel distributor (housing side). (See FUEL INJECTOR REMOVAL/INSTALLATION [13B-MSP].)

6.  Remove the A/C belt. (See DRIVE BELT REPLACEMENT [13B-MSP].)

7.  Remove the A/C compressor with the pipes connected and secure the A/C compressor using wire or rope so that it is out of the way.

8.  Disconnect the engine wiring harness from the main fuse block side.

9.  Remove the aerodynamic under cover. (See AERODYNAMIC UNDER COVER REMOVAL/INSTALLATION.)

10.  Remove the under cover. (See ENGINE OIL REPLACEMENT [13B-MSP].)

11.  Disconnect front ABS wheel speed sensor connector. (See FRONT ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION.)

12.  Remove the clutch release cylinder with the pipes connected and secure the clutch release cylinder using wire or rope so that it is out of the way. (MT) (See CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION.)

13.  Remove the shift lever component. (MT) (See TRANSMISSION REMOVAL/INSTALLATION [P66M-D].)

14.  Disconnect the radiator hose, the heater hose and coolant reserve tank hose.

15.  Disconnect the selector link. (AT) (See AUTOMATIC TRANSMISSION REMOVAL/INSTALLATION [SJ6A-EL].)

16.  Remove the engine, transmission, and crossmember component. (See ENGINE REMOVAL/INSTALLATION [13B-MSP].)

17.  Remove the extension manifold (upper and lower). (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [13B-MSP].)

18.  Remove the AIR control valve. (See SECONDARY AIR INJECTION (AIR) CONTROL VALVE REMOVAL/INSTALLATION [13B-MSP].)

19.  Remove in the order indicated in the table.

20.  Install in the reverse order of removal.

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1	Fuel hose (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [13B-MSP].)
2	Fuel distributor (intake manifold side) (See FUEL INJECTOR REMOVAL/INSTALLATION [13B-MSP].)
3	Intake manifold (See Intake Manifold Installation Note.)

Intake Manifold Installation Note

1.  Apply oil thoroughly to the APV as shown in the figure.

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2.  Tighten the bolts in the order shown in the figure

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3.  Retighten the No.1 bolt after tighten the all bolts.