Intake Manifold: Service and Repair

REMOVAL
1. Drain engine cooling system.
2. Disconnect battery ground cable.
3. Remove throttle body.
4. Disconnect fuel lines.
5. Remove fuel injector wiring harness from engine.
6. Disconnect upper radiator hose.
7. Disconnect water outlet heater hose.
8. Mark and remove distributor assembly.
9. Remove rocker arm covers.
10. Remove intake manifold attaching bolts/studs. Manifold assembly can be removed with fuel rails and injectors in place. Remove manifold side gaskets and end seals, and discard.

INSTALLATION
1. The intake manifold, cylinder head, and cylinder block mating surfaces should be clean and free of old silicone rubber sealer. Use a suitable solvent to clean these surfaces.

Intake Manifold/Block Sealer Locations:

2. Apply Silicone Rubber Sealer D6AZ-19562-AA or equivalent to intersection of cylinder block assembly and head assembly at four corners as shown.

NOTE: When using silicone rubber sealer, assembly must occur within 15 minutes after sealer application. After this time, the sealer may start to set-up, and its sealing effectiveness may be reduced. In high temperature/humidity conditions, RTV will start to "skin over" in approximately 5 minutes.

Intake Manifold Front Seal:

3. Install front intake manifold seal and rear intake manifold seal. Secure with retaining features.

Intake Manifold Gasket/Seal Placement:

4. Position intake manifold gaskets onto cylinder heads and insert locking tabs over tabs on cylinder head gaskets.
5. Apply Silicone Rubber Sealer D6AZ-19562-AA over gasket in same places as in Step 2.
6. Carefully lower intake manifold into position on cylinder block and cylinder heads to prevent disturbing the silicone sealer and causing gasketing voids.

Lower Intake Manifold Assembly:

7. Install bolts and tighten in the numerical sequence shown, to the following specifications in two steps:
a. 15 Nm (11 ft lb)
b. 24 Nm (18 ft lb)

NOTE: Lightly oil all attaching bolts and stud threads before installation.

8. Using new gaskets, install rocker arm covers and tighten to 10 Nm (7 ft lb). Install thermostat housing and new gasket. Tighten attaching bolts to 20-30 Nm (15-22 ft lb).
9. Install fuel injector wiring harness.
10. Install throttle body assembly and new gasket.
11. Connect PCV hose at throttle body and PCV valve.
12. Install electrical connectors to ECT and ACT sensors, distributor, and BPA solenoid.
13. Connect removed vacuum hoses to their original locations.
14. Install heater hose to elbow. Tighten hose clamp securely.
15. Install upper radiator hose to thermostat housing. Tighten hose clamp securely.
16. Connect fuel lines to fuel rail assembly, Check O-rings for wear and replace if necessary.
17. Install fuel line safety clips.
18. Install air cleaner outlet tube to throttle body. Tighten clamp securely.
19. Fill and bleed cooling system with specified coolant and proper mixture.

CAUTION: This engine has aluminum components and requires a special corrosion-inhibited coolant formulation to avoid radiator damage.

20. Connect battery ground cable.
21. Start engine and check for coolant, oil, or vacuum leaks.
22. Verify distributor initial timing. Adjust as necessary.
23. Check and, if necessary, adjust the engine idle speed, transmission throttle linkage (overdrive transmission only) and speed control.