Intake Manifold: Service and Repair

REMOVAL
Pre-removal Operation:
- Remove the intake manifold plenum.
- Fuel discharge prevention.

Follow removal steps outlined in illustration.

Removal Service Point
[A] Injector And Delivery Pipe Assembly.
Remove the delivery pipe with the injectors Fitted to the delivery pipe.

CAUTION: Do not drop the injectors when removing the delivery pipe.

INSPECTION
Intake Manifold
1. Check that the intake manifold is not damaged or cracked. If faulty, replace.
2. Check that the vacuum extraction port is not clogged. If faulty, clean.
3. Using a straight edge and thickness gauge, check the mounting surface for distortion.

Standard value: 0.15 mm (0.006 inch) or less
Limit: 0.2 mm (0.008 inch)

INSTALLATION
Installation in reverse order as removal.

Installation Service Points





]A[ Intake Manifold Gasket.
Install so that the projection on the gaskets is as shown in the diagram.





]B[ Intake Manifold.
1. Coat the intake manifold mounting studs with engine oil.





2. Tighten the intake manifold mounting nuts in the following sequence.





]C[ Fuel High Pressure Hose Connection.
1. When connecting the high-pressure fuel hose to the fuel rail, apply a drop of new engine oil to the O-ring, and then insert, being careful not to damage the O-ring.

CAUTION: Do not let engine oil in the fuel rail.

2. Check that the high-pressure fuel hose turns smoothly. If not, remove the hose and then re-insert it into the fuel rail and check again.
3. Tighten the bolts to the specified torque.

Post-Installation Operation:
- Install the intake manifold plenum.
- Fuel discharge prevention.