Intake Manifold: Service and Repair

Gaskets - inlet manifold
Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed.
Refer to Service Precautions.

Remove
1. Disconnect battery earth lead.
2. Remove air intake hose.
3. Remove LH ignition coil cover.
4. Remove RH ignition coil cover.





5. Disconnect multiplugs from ignition coils.





6. Disconnect multiplugs from throttle body, thermostat heater, CMP sensor and ECT sensor. Cut cable ties and release engine harness.





7. Disconnect multiplugs from VCC solenoids.
8. Release VCC multiplug harness from clip.





9. Disconnect multiplug from alternator.
10. Release alternator harness from 4 clips.





11. Disconnect multiplugs from KS and CMP sensor.





12. Remove 2 nuts securing fuel injector harness to fuel rail.
13. Release vacuum reservoir and mounting bracket from LH fuel injector harness securing stud.
14. Remove fuel hose and mounting bracket from LH fuel injector harness securing stud.
15. Release alternator harness from 2 clips on engine cover mounting brackets.





16. Disconnect multiplugs from fuel injectors.
17. Release engine harness from clips and move clear of camshaft cover.





18. Disconnect multiplug from charcoal canister purge solenoid valve.





19. Remove 2 nuts securing engine harness to inlet manifold





20. Disconnect multiplug from SAI solenoid.
21. Remove SAI solenoid valve from RH fuel injector harness securing stud.





22. Disconnect multiplug from knock sensor.
23. Remove washer from fuel injector harness securing stud.
24. Disconnect multiplugs from fuel injectors.
25. Reposition injector harness.
26. Remove air intake plenum.





27. Release terminal cover, remove nut and disconnect 2 cables from terminal post.
28. Depressurize fuel system.





29. Disconnect fuel feed hose from fuel rail.

CAUTION: Always fit plugs to open connections to prevent contamination.





30. Release 2 clips and disconnect 2 breather hoses.
31. Remove clip and disconnect brake vacuum hose.
32. Remove 2 bolts securing oil separator to manifold.





33. Remove clip and disconnect purge solenoid valve vacuum hose. Disconnect SAI vacuum pipe.





34. Remove 10 nuts securing inlet manifold to cylinder heads and remove 10 spacers.
35. Position brake servo vacuum pipe aside.





36. Lift inlet manifold and disconnect breather pipe.
37. Remove inlet manifold and discard 4 gaskets.

NOTE: Do not carry out further dismantling if component is removed for access only.

38. Disconnect vacuum pipe and remove solenoid valve.





39. Remove 4 bolts securing engine cover brackets and remove brackets from inlet manifold.





40. Remove bolt securing fuel rail to inlet manifold and remove fuel rail with injectors.
41. Remove and discard lower 'O' rings from injectors.





42. Remove 4 bolts securing throttle housing to inlet manifold and remove throttle body.
43. Remove and discard '0' ring from throttle housing.
44. Remove 6 Torx screws securing front cover to inlet manifold and remove front cover.
45. Remove and discard front cover 'O' ring.





46. Remove 3 bolts securing 2 brackets to manifold rear cover.
47. Remove 2 brackets.
48. Remove 4 Torx screws securing inlet manifold rear cover and remove cover.





49. Remove and discard 'O' ring.
50. Depress locking collars and remove vent pipe from inlet manifold.

Refit
1. Fit vent pipe to inlet manifold.
2. Fit new 'O' ring to rear cover.
3. Fit rear cover to inlet manifold and tighten 4 Torx screws to 10 Nm (7 ft. lbs.).
4. Fit 2 brackets and secure with 3 bolts and tighten to 10 Nm (7 ft. lbs.).
5. Fit new 'O' ring to front cover.
6. Fit front cover to manifold and tighten 6 Torx screws to 10 Nm (7 ft. lbs.).
7. Fit new throttle body seal.
8. Fit throttle housing to inlet manifold and tighten 4 bolts to 10 Nm (7 ft. lbs.).
9. Lubricate new '0' rings and fit to injectors.
10. Fit fuel rail with injectors to inlet manifold and fit bolt.
11. Fit 2 new brackets to manifold and tighten 5 bolts to 10 Nm (7 ft. lbs.).
12. Fit solenoid valve and connect vacuum pipe.
13. Fit 4 new gaskets and install inlet manifold.
14. Connect breather pipe and install inlet manifold to studs.
15. Position brake servo vacuum pipe.
16. Fit 10 spacers and tighten 10 inlet manifold securing nuts to 15 Nm (11 ft. lbs.).
17. Connect vacuum hose to inlet manifold front cover.
18. Connect brake vacuum hose and secure with clip.
19. Connect 2 breather hoses and secure with 2 clips.
20. Clean fuel hose connections.
21. Connect fuel feed hose to fuel rail.
22. Connect 2 cables to terminal post secure with nut and fit terminal cover.
23. Fit air intake plenum.
24. Position injector harness.
25. Fit washer to fuel injector harness securing stud.
26. Fit secondary air vacuum switching valve to RH fuel injector securing stud.
27. Fit 2 nuts securing fuel injector harness to inlet manifold and tighten.
28. Connect multiplug to charcoal canister purge solenoid valve.
29. Position and secure engine harness to brackets with clips.
30. Connect fuel injector harness multiplugs.
31. Connect alternator harness to 2 clips on engine cover mounting brackets.
32. Fit fuel hose and mounting bracket to LH fuel injector harness securing stud.
33. Fit vacuum reservoir and mounting bracket to LH fuel injector harness securing stud.
34. Fit 2 nuts securing fuel injector harness to inlet manifold and tighten.
35. Connect knock sensor multiplug.
36. Connect multiplug to CMP sensor.
37. Connect alternator harness to 4 clips.
38. Connect alternator multiplug.
39. Connect multiplug to charcoal canister purge solenoid valve.
40. Connect VCC multiplug harness to clip.
41. Connect multiplugs to valve body solenoids.
42. Fit new cable ties, align and secure harness.
43. Connect multiplug to CMP sensor.
44. Connect multiplug to throttle body.
45. Connect multiplugs to ECT sensors.
46. Connect multiplugs to ignition coils.
47. Fit coil cover.
48. Fit coil cover.
49. Connect air intake hose.
50. Connect battery earth lead.