Intake Manifold: Service and Repair

INTAKE MANIFOLD

Image Symbols:

WARNING: To avoid the danger of being scalded, never drain the engine coolant when the engine is hot.





1. Remove engine cover with power tool.
2. Release fuel pressure.
3. Remove air duct (inlet), power duct, air cleaner case and air duct and resonator assembly.
4. Drain engine coolant from radiator.

CAUTION:
^ Perform this step when the engine is cold.
^ Do not spill engine coolant on drive belts.





5. Disconnect fuel feed hose quick connector on engine side.
6. Remove fuel damper and fuel hose assembly.

CAUTION:
^ While hoses are disconnected, plug them to prevent fuel from draining.
^ Do not separate fuel damper and fuel hose.

7. Remove or disconnect harnesses, engine cover bracket (RH and LH), vacuum hose, EVAP tube and hose and PCV hose and tube from intake manifold (upper).





8. Loosen mounting bolts in reverse order as shown in the figure to remove intake manifold (upper) with power tool.
<-: Engine front
9. Remove electric throttle control actuator as follows:
a. Disconnect harness connector.
b. Loosen mounting bolts diagonally.

CAUTION:
^ Handle carefully to avoid any shock to electric throttle control actuator.
^ Do not disassemble.

10. Remove fuel injector and fuel tube assembly.
11. Disconnect water hoses from intake manifold adaptor.





12. Loosen mounting bolts in reverse order as shown in the figure to remove intake manifold (lower) with power tool.
<-: Engine front
13. Remove intake manifold adaptor from intake manifold (lower).
14. Remove intake manifold gaskets.

CAUTION: Cover engine openings to avoid entry of foreign materials.

INSPECTION AFTER REMOVAL
Surface Distortion





^ Check the surface distortion of both the intake manifold (upper and lower) mating surfaces with straightedge and feeler gauge.
Limit: 0.1 mm (0.004 inch)
^ If it exceeds the limit, replace intake manifolds (lower and/or upper).

INSTALLATION
Note the following, and install in the reverse order of removal.

Intake Manifold (Lower)





Tighten in numerical order as shown in the figure.
<-: Engine front
^ There are two types of mounting bolts. Refer to the following for locating bolts.
M8 x 90 mm (3.54 inch) 7, 8
M8 x 35 mm (1.38 inch) Except the above

Intake Manifold (Upper)





Tighten in numerical order as shown in the figure.
<-: Engine front

Electric Throttle Control Actuator
^ Install gasket with its directional protrusion set up/downward.
^ Tighten mounting bolts of electric throttle control actuator equally and diagonally in several steps.
^ After installation perform procedure in EM-182, INSPECTION AFTER INSTALLATION.

Water Hose
Insert hose by 27 to 32 mm (1.06 to 1.26 inch) from connector end.

INSPECTION AFTER INSTALLATION
^ Perform the Throttle Valve Closed Position Learning when harness connector of electric throttle control actuator is disconnected. Refer to EC-744, Throttle Valve Closed Position Learning. Throttle Valve Closed Position Learning
^ Perform the Idle Air Volume Learning and Throttle Valve Closed Position Learning when electric throttle control actuator is replaced. Refer to EC-744, Idle Air Volume Learning. Programming and Relearning