Intake Manifold: Service and Repair

INTAKE MANIFOLD




REMOVAL AND INSTALLATION

REMOVAL SERVICE POINT

[[A]] FUEL RAIL AND INJECTOR REMOVAL

CAUTION: Care must be taken when removing the fuel rail not to drop the injector.

Remove the fuel rail with the injectors attached to it.

INSTALLATION SERVICE POINTS




]]A[[ INTAKE MANIFOLD GASKET INSTALLATION
Install the gasket with the protrusions in the position illustrated.

]]B[[ INTAKE MANIFOLD INSTALLATION
1. Coat the intake manifold mounting studs with engine oil.







2. Tighten the intake manifold mounting nuts by the given procedure.

]]C[[ FUEL HIGH-PRESSURE HOSE INSTALLATION

CAUTION:
- Be careful not to allow any engine oil to enter the fuel rail.
- Be careful not to bend the fuel high-pressure hose as it is made of plastics.




1. When connecting the fuel high-pressure hose to the fuel rail, apply a small amount of new engine oil to the O-ring and then insert the fuel high-pressure hose, being careful not to damage the O-ring.
2. While turning the fuel high-pressure hose to the left and right, install it to the fuel rail.
3. Check that the injector turns smoothly. If it does not turn smoothly, the O-ring may be trapped. Remove the fuel high-pressure hose and then re-insert it into the fuel rail and check again.

INSPECTION
Check the following points; replace the part if a problem is found.

Intake Manifold Check
1. Check for damage or cracking of any part.
2. Clogging of the negative pressure (vacuum) outlet port, or clogging of the exhaust gas recirculation passages.
3. Using a straight edge and feeler gauge, check for distortion of the cylinder head installation surface.

Standard value: 0.15 mm (0.006 inch) or less
Limit: 0.20 mm (0.008 inch)