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INTAKE MANIFOLD REMOVAL/INSTALLATION

BHE011301005W08

  Warning

  • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
  • Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can ignite and cause serious injury or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure" when servicing the fuel system. (See BEFORE REPAIR PROCEDURE.)
  • Remove the engine, transmission and crossmember carefully, holding it steady. If the transmission falls it could be damaged or cause injury.
  • After disconnecting the steering shaft joint, always set the EPS system to the neutral position to prevent system malfunction. (See EPS SYSTEM NEUTRAL POSITION SETTING.)

  Note

  • The engine must be removed to remove the intake manifold.
  • Remove the engine, transmission, and crossmember component as a single unit downward of the vehicle.

1. Remove the following parts:

  (1) The front wheel and tires (SeeGENERAL PROCEDURES (SUSPENSION)
  (2) The engine cover (SeeENGINE COVER REMOVAL/INSTALLATION.)
  (3) The front suspension tower bar (SeeFRONT SUSPENSION TOWER BAR REMOVAL/INSTALLATION.)
  (4) The battery cover, battery, battery box and battery tray (SeeBATTERY REMOVAL/INSTALLATION.)
  (5) The air cleaner, intake-air duct and air cleaner insulator (SeeINTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
  (6) The PCM (See PCM REMOVAL/INSTALLATION.)
  (7) The secondary air injection pump. (See SECONDARY AIR INJECTION (AIR) PUMP REMOVAL/INSTALLATION.)

2. Drain the engine coolant. (SeeENGINE COOLANT REPLACEMENT.)

3. Disconnect the brake vacuum hose.

4. Disconnect the quick release connector going to the charcoal canister from the engine room side. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION.)

5. Disconnect the plastic fuel hose. (See BEFORE REPAIR PROCEDURE.) (See FUEL INJECTOR REMOVAL/INSTALLATION.)

6. Remove the ignition coil. (See IGNITION COIL REMOVAL/INSTALLATION.)

7. Remove the A/C belt. (See DRIVE BELT REPLACEMENT.)

8. Remove the A/C compressor with the pipes connected and secure the A/C compressor using wire or rope so that it is out of the way.

9. Disconnect the engine wiring harness from the main fuse block side.

10. Remove the engine under cover.

11. Disconnect front ABS wheel speed sensor connector. (See FRONT ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION.)

12. Disconnect the radiator hose, the heater hose and coolant reserve tank hose.

13. Remove the clutch release cylinder with the pipes connected and secure the clutch release cylinder using wire or rope so that it is out of the way. (MT) (See CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION.)

14. Remove the shift lever component. (MT) (See TRANSMISSION REMOVAL/INSTALLATION [R15M-D].) (See TRANSMISSION REMOVAL/INSTALLATION [Y16M-D].)

15. Disconnect the selector link. (AT) (See AUTOMATIC TRANSMISSION REMOVAL/INSTALLATION.)

16. Remove the engine, transmission, and crossmember component using an engine lifter. (See ENGINE REMOVAL/INSTALLATION.)

17. Remove the extension manifold (upper and lower). (SeeINTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)

18. Remove the AIR control valve. (See SECONDARY AIR INJECTION (AIR) CONTROL VALVE REMOVAL/INSTALLATION.)

19. Remove in the order indicated in the table.

20. Install in the reverse order of removal.

1 | Fuel hose (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION.)
2 | Fuel distributor (primary 2, secondary)
3 | Intake manifold (See Intake Manifold Installation Note.)

## Intake Manifold Installation Note

1. Apply oil thoroughly to the APVs (13B-MSP (HIGH POWER)) as shown in the figure.

2. Tighten the bolts in the order shown in the figure

3. Retighten the No.1 bolt after tighten the all bolts.

  Tightening torque
  18.6-25.5 N·m {1.8-2.6 kgf·m, 13.7-18.9 ft·lbf}