Intake Manifold: Service and Repair
A: REMOVAL
1) Release fuel pressure.
2) Disconnect battery ground cable.
3) Disconnect connector from mass air flow sensor.
4) Loosen clamp which connects air intake chamber to throttle body.
5) Remove two clips of air cleaner upper cover.
6) Disconnect blow-by hose from air intake duct.
7) Disconnect air hoses, and remove air intake chamber.
8) Remove air intake duct, air cleaner upper cover and air intake chamber as a unit.
9) Remove air cleaner element.
10) Disconnect accelerator cable (A).
11) Disconnect cruise control cable (B). (With cruise control model)
12) Remove power steering pump from bracket.
(1) Remove V-belt covers.
(2) Loosen lock bolt and slider bolt, and remove power steering pump drive V-belt.
(3) Remove bolts which secure power steering pipe brackets to intake manifold.
NOTE: Do not disconnect power steering hose.
(4) Remove bolts which install power steering pump to bracket.
(5) Place power steering pump on the right side wheel apron.
13) Disconnect spark plug cords from ignition coil.
14) Disconnect PCV hose (A) and vacuum hose (B) from intake manifold.
15) Disconnect vacuum hose (C) to cruise control diaphragm. (With cruise control models)
16) Disconnect engine coolant hose from throttle body.
17) Disconnect engine coolant hose (A) from idle air control solenoid valve.
18) Disconnect air by-pass hose (B) from idle air control solenoid valve.
19) Disconnect brake booster hose.
20) Remove EGR pipe.
21) Remove engine harness bracket from transmission housing, and disconnect engine harness connectors from bulkhead harness connectors.
22) Disconnect connectors from engine coolant temperature sensor (A) and thermometer (B).
23) Disconnect knock sensor connector.
24) Disconnect connector from camshaft position sensor.
25) Disconnect connector from crankshaft position sensor.
26) Disconnect connector from oil pressure switch.
27) Disconnect fuel hoses from fuel pipes.
WARNING: Catch fuel from hoses in a container.
28) Remove bolts which hold intake manifold onto cylinder heads.
29) Remove intake manifold.
B: DISASSEMBLY
1) Disconnect engine ground terminal from intake manifold.
2) Disconnect connectors from throttle position sensor, ignition coil, fuel injectors, idle air control solenoid valve, purge control solenoid valve and EGR solenoid valve.
3) Remove engine harness from intake manifold.
4) Remove idle air control solenoid valve from intake manifold.
5) Remove throttle body from intake manifold.
6) Remove fuel pipes, etc. from intake manifold.
7) Remove EGR solenoid valve and purge control solenoid valve.
C: ASSEMBLY
1) Install EGR solenoid valve and purge control solenoid valve.
2) Assemble fuel pipes, etc. to intake manifold.
3) Assemble throttle body to intake manifold.
CAUTION: Replace gasket with a new one.
Tightening torque: 22 ± 2 N.m (2.2 ± 0.2 kg-m, 15.9 ± 1.4 ft-lb)
4) Install idle air control solenoid valve to intake manifold.
CAUTION: Replace gasket with a new one.
Tightening torque: 6.4 ± 0.5 N.m (0.65 ± 0.05 kg-m, 4.7 ± 0.4 ft-lb)
5) Install engine harness onto intake manifold.
6) Connect connectors to throttle position sensor, ignition coil, fuel injectors, idle air control solenoid valve, purge control solenoid valve and EGR solenoid valve.
7) Connect engine ground terminal to intake manifold.
D: INSTALLATION
1) Install intake manifold onto cylinder heads.
CAUTION: Always use new gaskets.
Tightening torque: 25 ± 2 N.m (2.5 ± 0.2 kg-m, 18.1 ± 1.4 ft-lb)
2) Connect fuel hoses.
3) Connect connector to oil pressure switch.
4) Connect connector to crankshaft position sensor.
5) Connect connector to camshaft position sensor.
6) Connect knock sensor connector.
7) Connect connectors to engine coolant temperature sensor (A) and thermometer (B).
8) Install engine harness bracket, and connect engine harness connectors to bulkhead connectors.
9) Install EGR pipe.
Tightening torque: 34 ± 2 Nm (3.5 ± 0.2 kg-m 25.3 ± 1.4 ft.lb)
10) Connect brake booster hose.
11) Connect engine coolant hose (A) to idle air control solenoid valve.
12) Connect air by-pass hose (B) to idle air control solenoid valve.
13) Connect engine coolant hose to throttle body.
14) Connect vacuum hose (C) to cruise control diaphragm. (With cruise control models)
15) Connect PCV hose (A) and vacuum hose (B) to intake manifold.
16) Connect spark plug cords to ignition coil.
17) Install power steering pump on bracket.
(1) Install power steering pump on bracket, and tighten bolts.
Tightening torque: 20.1 ± 2.5 N.m (2.05 ± 0.25 kg-m, 14.8 ± 1.8 ft-lb)
(2) Install power steering pipe brackets on right side intake manifold.
(3) Install power steering pump drive V-belt.
(4) Adjust V-belt.
(5) Install V-belt covers.
18) Connect accelerator cable (A).
19) Connect cruise control cable (B). (With cruise control models)
20) Install air cleaner element.
21) Install air cleaner upper cover, air intake duct and air intake chamber as a unit.
CAUTION: Before installing air cleaner upper cover, align holes with protruding portions of air cleaner lower case, then secure upper cover to lower case.
22) Tighten bolts which install air intake chamber to stays.
Tightening torque: 4.9 ± 0.5 N.m (0.5 ± 0.05 kg-m, 3.6 ± 0.4 ft-lb)
23) Connect connector to mass air flow sensor.
24) Connect connector to fuel pump relay.
25) Connect battery ground cable.