Intake Manifold: Service and Repair

INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [L5]

WARNING:
- A hot engine and intake air system can cause severe burns. Turn off the engine and wait until they are cool before removing the intake air system.
- Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can ignite and cause serious injury or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure".

1. Complete the "BEFORE SERVICE PRECAUTION". Before Service Precaution

2. Disconnect the negative battery cable. Removal and Replacement

3. Remove the plug hole plate. Service and Repair

4. Disconnect the wiring harness.

5. Remove in the order indicated in the table.

6. Install in the reverse order of removal.

7. Add the engine coolant to the cooling system filler neck and the coolant reserve tank to replace that during servicing.

8. Inspect the engine coolant level. Engine Coolant Level Inspection

9. Inspect for engine coolant leakage. Engine Coolant Leakage Inspection

10. Complete the "AFTER SERVICE PRECAUTION". After Service Precaution

Step 1










Step 2










Resonance Chamber Removal Note

1. Remove the mudguard.

2. Remove the resonance chamber.

Throttle Body Removal Note

WARNING:
- Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while the pressure escapes.
- When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and remove it.

CAUTION:
- Do not plug the water hose with a sharp-edged object. Otherwise, the hose could be damaged.

1. Wrap a clean cloth around the cooling system cap and release the pressure by loosening the cap slowly.

2. Remove the water hose from the throttle body and plug the water hose quickly.

Intake Manifold Removal Note

1. Remove the coolant reserve tank. Service and Repair

2. Remove the fan control module No.2. Service and Repair

3. Remove the under cover.

4. Remove all clips for securing wiring harnesses from the intake manifold.

5. Disconnect the vacuum hoses connecting the intake manifold. Service and Repair

6. Remove the fuel distributor and fuel injector a as single unit. Service and Repair

7. Remove the intake manifold.

Throttle Body Installation Note

1. Temporarily tighten the throttle body to the intake manifold.

2. Tighten the installation bolts in the order shown in the figure.






Throttle body tightening torque
- 8-11.5 Nm {82-117 kgf-cm, 71-101 in-lbf}

3. Remove the plug from the engine coolant hose and install the water hose to the throttle body quickly.

Air Hose Installation Note

1. Adjust the convex of the throttle body and the air hose.