Intake Manifold: Service and Repair

Removal
1. Release fuel pressure in fuel feed line.

CAUTION: This work must not be done when engine is hot. If done so, it may cause adverse effect to catalyst.

2. Disconnect negative cable at battery.





3. Drain coolant.

WARNING: To help avoid danger of being burned, do not remove drain plug and radiator cap while engine and radiator are still hot. Scalding fluid and steam can be blown out under pressure if plug and cap are taken off too soon.

4. Remove strut tower bar.
5. Disconnect coupler from intake air temperature sensor.





6. Remove surge tank cover (1).





7. Remove air cleaner upper case, intake air hose, intake air pipe (1) and surge tank pipe (2) as one component. Do not disassemble them, when removing and reinstalling.
8. Disconnect accelerator cable (1) and A/T throttle cable (for A/T vehicle) (2) from throttle body.





9. Disconnect water hose (3) from throttle body.
10. Disconnect injector wire (1) coupler.





11. Disconnect brake booster hose (2) from intake manifold.
12. Disconnect couplers of TP sensor (1), MAF sensor (2) and IAC valve (3).
13. Disconnect earth terminal (4) from intake collector.





14. Remove clamp bracket (5) from intake collector.
15. Disconnect couplers from manifold absolute pressure sensor, EVAP canister purge valve and EGR valve.
16. Disconnect PCV hose from cylinder head cover.
Disconnect breather hoses from throttle body or cylinder head cover.
17. Disconnect hoses of EVAP canister purge valve and heater.





18. Remove EGR pipe.





19. Disconnect hoses of heater, EVAP canister, tank pressure control solenoid valve, fuel feed and fuel return.





20. Remove throttle body (1) and intake collector (2) from intake manifold (3).
21. Disconnect hoses of IAC valve and EVAP canister purge valve from intake collector.





22. Remove throttle body (2) from intake collector.
23. Remove IAC valve, EGR valve and EVAP canister purge valve from intake collector.
24. Remove intake manifold bolts (8 pc.) and nuts (4 pc.).





25. Remove intake manifold.

Installation





1. Install new intake manifold gaskets (1) to cylinder heads.





2. Install intake manifold (1). Tighten bolts and nuts to specified torque.





3. Install throttle body (2) to intake collector (1) with new throttle body gasket. Tighten bolts and nuts to specified torque.





4. Install IAC valve (1), EGR valve (2), EVAP canister purge valve (3), manifold absolute pressure sensor, clamps and each hoses to intake collector and throttle body if removed. Use new gasket, when installing IAC valve and EGR valve.
5. Install throttle body and intake collector assembly to intake manifold with new intake collector gaskets.





6. Connect heater hose (1), EVAP canister hose (4), tank pressure control solenoid valve hose, fuel feed hose (2) and fuel return hose (3).
7. Install EGR pipe (3) with new gaskets.
8. Connect EVAP canister purge valve hose (4) and heater hose (5).
9. Connect PCV hose (6), breather hose (8) and water hose (7).





10. Connect couplers of manifold absolute pressure sensor, EVAP canister purge valve (1) and EGR valve (2). Fix wire harness with clamps.
11. Install clamp bracket (5) to intake collector.
12. Connect earth terminal (4) to intake collector.





13. Connect TP sensor coupler (1), MAF sensor coupler (2) and IAC valve coupler (3).
14. Connect brake booster hose (2) to intake manifold.





15. Connect injector wire (1) coupler.
16. Connect water hoses (3) to throttle body.





17. Connect accelerator cable (1) and A/T throttle cable (for A/T vehicle) (2) to throttle body and adjust these cables.





18. Install surge tank pipe (2) to intake manifold with new gaskets and intake air pipe (1) to throttle body.





19. Install surge tank cover (1).
20. Install air cleaner upper case.
21. Connect coupler to intake air temp. sensor.





22. Instal1strut tower bar (1).
23. Check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not been reinstalled.
24. Refill cooling system.
25. Connect negative cable at battery.
26. Upon completion of installation, verify that there is no fuel leakage at each connection according to procedure.