Intake manifold — removal and installation

Removal

1. Relieve fuel system pressure. Refer to Section 310-00 for additional information.

2. Disconnect the ground cable from the battery. For additional information, refer to Section 414-01.

3. Release the power steering fluid reservoir and set it aside.



4. Loosen the drive belt tension and remove it.



5. Remove the air filter together with the air intake hose.

• 1.Air intake hose
• 2. Disconnect the mass air flow sensor (MAF sensor) connector.
• Disconnect the PCV hose from the cylinder head cover.

6. Disconnect the plug connector.

• 1. Ignition coil (EI)
• 2. Capacitor

7. Disconnect the connector and disconnect the hose.

• 1. Idle Air Control (IAC) Valve Connector
• 2. Forced crankcase ventilation

8. Disconnect the hoses and disconnect the plug connectors.

• 1. Brake booster vacuum hose
• 2.Vacuum hose - fuel pressure control
• 3. Throttle position sensor (TP sensor) plug connector
• 4.Knock sensor (KS) plug connector

9. Release the wiring harness.




10. Disconnect the accelerator cable.

• 1.Remove the clamp.
• 2. Unscrew the cable from the bracket.

11. Release the hose bracket and set it aside.



12. Disconnect the injector plug connectors and place the engine wiring harness on the cylinder head cover. Release the injector connector clamps.




13. Disconnect the generator.



14.

NOTE: Fuel supply line nipples are painted white or identified by a white ring. Fuel return line nipples are painted red or identified by a red ring.

Disconnect the fuel lines.



15. Disconnect the fuel manifold. Remove the two bolts.



16.

NOTE: Follow the operating sequence.

Disconnect the intake manifold. Disconnect the oil level indicator tube bracket.



17. Disconnect the vacuum line of the carbon filter. Remove the intake manifold.

Installation

1. Align the intake manifold and install the EVAP canister vacuum line.



2. Install the intake manifold. Use a new two-piece gasket. Install the oil dipstick bracket.



3.

CAUTION: Do not apply silicone grease to the injector O-rings as this may cause the injectors to clog.

NOTE: Install new injector O-rings.

Install the fuel rail. Apply clean engine oil to the injector O-rings before installation.



4. Connect the fuel lines.



5. Connect the generator.



6. Connect the injector connector.



7. Fix the hose bracket in the required position.



8. Connect the accelerator cable.

• 1.Install the clamp.
• 2. Screw the cable into the bracket.

9. Fix the wiring harness in the required position.



10. Connect the hoses and match the plug connectors.

• 1. Brake booster vacuum hose
• 2.Vacuum hose - fuel pressure control
• 3. Throttle position sensor (TP sensor) plug connector
• 4.Knock sensor (KS) plug connector

11. Connect the connector and attach the hose.

• 1.IAC valve connector
• 2.Crankcase ventilation

12. Connect the plug connector.

• 1. Ignition coil (EI)
• 2. Capacitor

13. Install the air filter together with the air intake hose.

• 1.Air intake hose
• 2.MAF plug connector
• Connect the PCV hose to the cylinder head cover.

14. Install and tighten the drive belt.



15. Secure the power steering fluid reservoir.



16. Connect the ground cable to the battery. For additional information, refer to Section 414-01.