Intake Manifold Assembly

REMOVAL






1. Remove Data Link Connector 1 (DLC1) bracket as follows:
(a) Disconnect the DLC1 from the bracket.
(b) Disconnect the Vacuum Solenoid Valve (VSV) connector.
(c) Disconnect these hoses:
- Power Steering (PS) air hose (1) from air intake chamber.
- Vacuum sensing hose (2) from air intake chamber.
- Vacuum sensing hose (3) from fuel pressure regulator.
(d) Remove the bolt, DLC1 bracket and VSV assembly.






2. Remove EGR pipe.






3. Remove oil dipstick and guide for transmission as follows:
(a) Remove the bolt.
(b) Pull out the dipstick guide together with the dipstick.
(c) Remove the O-ring from the dipstick guide.






4. Disconnect these vacuum hoses:
- Vacuum hose (from actuator) from No.1 vacuum pipe.
- Vacuum hose from air intake chamber.
- Vacuum hose from hose clamp.
- Brake booster vacuum hose from union.






5. Disconnect the 2 vacuum hoses from the vacuum control valve set, then remove the 2 nuts, and disconnect the No.2 vacuum pipe from the air intake chamber and intake manifold.






6. Remove air intake chamber as follows:
(a) Disconnect the accelerator cable from the bracket.
(b) Remove the union bolt, brake booster union and 2 gaskets.
(c) Remove the 2 bolts, accelerator cable bracket and hose clamp.






(d) Remove the 2 bolts holding the chamber stays to the air intake chamber.
(e) Remove the 4 bolts and 2 nuts holding the intake air connector to the air intake chamber.
(f) Remove the 2 nuts holding the throttle body bracket to the cylinder head.






(g) Remove the 5 bolts, nut, air intake chamber and 2 gaskets.






7. Remove VSV set as follows:
(a) Disconnect the VSV connector.
(b) Remove the 2 nuts and vacuum control valve set.






8. Remove the vacuum hose, screw and VSV from the vacuum tank.

9. Remove fuel pressure pulsation damper, refer to Powertrain Management.
10. Remove fuel pipes as follows:
(a) Remove the 2 clamp bolt from the intake manifold.
(b) Remove the 2 union bolts and 4 gaskets, and disconnect the fuel inlet pipe and fuel return pipe.

NOTE:
- Put a suitable container or shop rag under the delivery pipe.
- Slowly loosen the union bolt.

11. Remove delivery pipe and injectors, refer to powertrain Management.






12. Remove the 6 intake manifold bolts and 2 nuts, then the manifold and gasket.



INSTALLATION
Installation is the reverse of removal, noting the following information:
- Tighten the air intake chamber to 27 Nm (280 kg.cm, 20 ft.lb).
- Tighten the vacuum control valve set to 21 Nm (210 kg.cm, 15 ft.lb).
- Tighten the vacuum pipe from the air intake chamber and intake manifold to 27 Nm (280 kg.cm, 20 ft.lb).
- Tighten the throttle body bracket to the cylinder head to 21 Nm (210 kg.cm, 15 ft.lb).
- Tighten intake air connector to the air intake chamber to 27 Nm (280 kg.cm, 20 ft.lb).
- Tighten chamber stays to the air intake chamber to 18 Nm (185 kg.cm, 13 ft.lb).
- Tighten brake union bolt to 29 Nm (300 kg.cm, 22 ft.lb).

NOTE:
- Use 2 new gaskets on brake union bolt.
- Use new O-rings on dip stick tubes, apply soapy water on the O-ring.