Intake Manifold: Service and Repair
DISASSEMBLYAUXILIARY PARTS (TURBO)
1. Remove in the sequence shown in the figure referring to the Disassembly Note.
2. Inspect all parts and repair or replace as necessary.
Caution: Place a rag between the SST and the vacuum pipes to protect the pipes.
Engine Harness and Vacuum Piping
Remove the engine harness and vacuum piping as an assembly.
Installation
Install in reverse sequence
Engine Harness and Vacuum Piping
1. Install the engine harness and vacuum piping as an assembly.
Tightening torque: 19-25 N.m (1.9-2.6 m-kg, 14-19 ft-lb)
2. Connect the heat gauge unit connector and ground.
3. Connect the evaporative hoses to the intermediate housing and oil filler pipe.
Dynamic Chamber Bracket
1. Install the dynamic chamber bracket.
Tightening torque: 19-25 N.m (1.9-2.6 m-kg, 14-19 ft-lb)
2. Connect the knock sensor connector and mount it to the bracket.
Intake Manifold
1. Install the new intake manifold gasket and new 0-rings on the engine.
2. Install the intake manifold.
Tightening torque: 19-25 N.m (1.9-2.6 m-kg, 14-19 ft-lb)
Housing Oil Nozzle and Manifold Oil Nozzle
Install the oil nozzles and connect the metering oil tubes with new washers. Refer to TSB 104498.
Tightening torque: 16-23 N.m (1.6-2.3 m-kg, 12-17 ft-lb)
Note: The oil tube ends are colored.
White for front rotor housing
Yellow for rear rotor housing
Blue for front inlet port
Green for rear inlet port
Air Tube
Install the air tube assembly and connect the tubes to the oil nozzles.
Air Control Valve (ACV)
1. Install the check valve and the new gasket.
2. Install the air control valve so that the check valve does not fall from the intake manifold.
3. Connect the couplers of the split air solenoid valve and the port air solenoid valve.
Tightening torque: 7.8-11 N.m (80-110 cm-kg, 69-95 in-lb)
Primary Fuel Injectors and Distribution Pipe
1. Apply engine oil to the 0-ring of the air bleed socket.
2. Insert the mixing plate into the intermediate housing with plate's tab faced upward.
3. Insert the air bleed socket and injector insulator into the intermediate housing.
4. Apply engine oil to the injector 0-rings, and install the primary fuel injectors.
5. Install the fuel distribution pipe and the insulator.
Tightening torque: 19-25 N.m (1.9-2.6 m-kg, 14-19 ft-lb)
6. Connect the fuel hoses.
7. Connect the injector couplers.
Throttle and Dynamic Chamber
1. Install the throttle and dynamic chamber assembly and the new gasket.
Tightening torque: 19-25 N.m (1.9-2.6 m-kg, 14-19 ft-lb)
2. Install the second vacuum piping on the intake manifold.
3. Connect the vacuum hoses and water hoses.
4. Connect the following connectors:
(1) Intake air temperature sensor
(2) Throttle sensor
(3) Air supply solenoid valve
(4) Bypass air control valve
(5) Air bypass solenoid valve
Metering Oil Tube
Connect the oil tubes so that the colors of the tube ends match the numbers as shown.
1 White
2 Blue
3 Green
4 Yellow
Tightening torque: 9.8-14 N.m (100-140 cm-kg, 87-122 in-lb)