Intake Manifold

REMOVAL & INSTALLATION

3000GT

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Relieve the fuel system pressure.
3. Disconnect battery negative cable.
4. Drain the cooling system.
5. Remove or disconnect the following:
   • Air intake hoses
   • Accelerator cables from the throttle body
   • Vacuum hoses, label
   • Harness connectors from the upper intake plenum
   • Clutch booster vacuum hose connection, if equipped
   • EGR components on California vehicles
   • Plenum retaining bracket
   • Plenum retaining nuts and bolts and remove the air intake plenum
   • High pressure and return fuel hoses
   • Fuel injector connectors and the pressure regulator vacuum line
   • Fuel rail with the injectors attached
   • Timing belt upper cover
   • Intake manifold mounting nuts
   • Intake manifold

   To install:

6. Thoroughly clean the mating surfaces of the heads, intake manifold and air intake plenum.
7. Install new intake manifold gaskets to the heads with the adhesive side facing up.
8. Place the manifold on the heads and install the cone disc springs and/or lockwashers.
9. Lubricate the studs lightly with oil, then install the nuts following this procedure:
   • Front bank: 48–72 inch lbs. (3–5 Nm).
   • Rear bank: 14–17 ft. lbs. (20–23 Nm).
   • Front bank: 14–17 ft. lbs. (20–23 Nm).
   • Repeat both banks: 14–17 ft. lbs. (20–23 Nm).
10. Install or connect the following:
    • Timing belt upper cover
    • Fuel rail assembly
    • Fuel injector connectors and the pressure regulator vacuum line
    • Fuel hoses, with new O-rings
    • Plenum. Tighten the retaining nuts and bolts evenly and gradually to 13 ft. lbs. (18 Nm).
    • Retaining bracket
    • EGR components on California vehicles
    • Upper intake harness connectors and vacuum hoses
    • Adjust the accelerator cables
    • Air intake hoses
11. Fill the system with coolant.
12. Connect the negative battery cable.

Diamante

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Relieve the fuel system pressure.
3. Remove or disconnect the following:
   • Negative cable and drain the cooling system
   • Air intake hose(s)
   • Accelerator control cables from the throttle body
   • Vacuum hoses including the brake booster hose
   • Wiring harness connectors
   • High pressure and return fuel hoses
   • EGR pipe and remove the EGR valve and EGR temperature sensor from the intake plenum assembly
   • MAP sensor, if equipped
   • Plenum retaining bracket
   • Plenum retaining nuts and bolts and remove the air intake plenum from the intake manifold
   • Upper timing belt covers
   • Water pump stay bracket

   NOTE: It is not necessary to remove the fuel injectors from the intake unless the manifold assembly is being replaced.

4. Remove or disconnect the following:
   • Fuel rail with the injectors attached
   • Coolant hoses from the intake manifold
   • Intake manifold mounting nuts and remove the intake manifold
5. Clean the gasket mounting surfaces.

   To install:

6. Thoroughly clean the mating surfaces of the heads, intake manifold and air intake plenum.
7. Install new intake manifold gaskets to the cylinder heads with the adhesive side facing up.
8. Place the manifold on the cylinder heads.
9. Lubricate the studs lightly with oil and install the nuts.
10. Tighten the mounting nuts as follows:
    • Front bank nuts: 48–72 inch lbs. (5–8 Nm).
    • Rear bank nuts: 14–17 ft. lbs. (20–23 Nm).
    • Front bank nuts: 14–17 ft. lbs. (20–23 Nm).
11. Connect the coolant hoses to the intake manifold.
12. Using new O-rings, install the fuel rail assembly, if removed. Tighten the mounting bolts to 84–108 inch lbs. (10–13 Nm).
13. Install or connect the following:
    • Plenum, with new gasket. Tighten the retaining nuts and bolts evenly and gradually to 13 ft. lbs. (18 Nm).
    • Retaining bracket and tighten the retaining bolts to 13 ft. lbs. (18 Nm)
    • MAP sensor, if removed
    • EGR valve, using a new gasket. Tighten the bolts to 16 ft. lbs. (22 Nm)
    • EGR temperature sensor and tighten the fitting to 84–108 inch lbs. (10–12 Nm)
    • EGR pipe and tighten the fittings to 43 ft. lbs. (60 Nm)
    • High pressure fuel hose, use a new O-ring. Tighten the retaining bolts to 48 inch lbs. (5 Nm).
    • Fuel return hose, using a new clamp
    • Water pump stay bracket
    • Upper timing belt covers
    • Harness connectors and vacuum hoses
    • Accelerator cables, adjust
    • Air intake hose(s)
14. Fill the system with coolant.
15. Connect the negative battery cable.

Eclipse

2.0L (4G63) ENGINE

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Relieve the fuel system pressure.
3. Remove the battery.
4. Drain the engine coolant.
5. Remove or disconnect the following:
   • Accelerator cable
   • Air intake hose
   • Ignition coil and the module wiring connectors
   • MAP sensor
   • Condenser
   • TP sensor and the IAC motor connectors
   • Knock sensor and the ECT sensor connectors
   • CMP sensor and the CKP sensor connectors
   • Air conditioning compressor connector
   • Engine control wiring harness bracket and position the harness out of the way
   • Vacuum hoses, label for reference
   • Spark plug wires from the ignition coil
   • Fuel lines from the fuel rail
   • Heater hoses
   • Fuel rail assembly and insulators
   • Ignition coil and module
   • EGR valve assembly
   • Intake manifold stay and the engine hanger
   • Intake manifold and gasket

   To install:

   Fig. 3: Exploded view of the intake manifold and related components — 2.0L (4G63) engine

6. Install or connect the following:
   • Intake manifold
   • Intake manifold stay and the engine hanger
   • EGR assembly
   • Ignition coil and module
   • Fuel rail and insulators
   • Heater hoses and fuel lines
   • Spark plug wires to the coil towers
   • Vacuum hoses
   • MAP sensor
   • TP sensor and the IAC motor connectors
   • Knock sensor and the ECT sensor connectors
   • CMP sensor and the CKP sensor connectors.
   • Ignition condenser
   • Accelerator cable, adjust
   • Battery
7. Refill the engine with coolant.
8. Start the engine and check for leaks.

2.0L (420A) ENGINE

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Disconnect the negative battery cable.
3. Drain the engine coolant.
4. Remove or disconnect the following:
   • Vacuum reservoir, if equipped with cruise control
   • Air intake hose and breather hose
   • Accelerator cable from the bracket
   • Engine harness retaining clips
   • MAP sensor
   • IAT sensor
   • Vacuum hose connection
   • TP sensor and the IAC motor connectors
5. Position the engine control wiring harness out of the way.
6. Remove or disconnect the following:
   • Alternator wiring harness connector
   • PCV hose assembly
   • Vacuum hoses, label for reference
   • EGR pipe connection
   • Fuel lines from the fuel rail
   • Intake manifold stay and the engine hanger
   • Throttle body
   • Intake manifold plenum and gasket
   • Injector connectors
   • Fuel rail with the injectors
   • Intake manifold

     Fig. 4: Intake manifold and related components — 2.0L (420A) engine

   To install:

7. Install or connect the following:
   • Intake manifold
   • Fuel rail assembly and connect the injectors
   • Intake plenum
   • Throttle body
   • Intake manifold stay and the engine hanger
   • Fuel lines to the fuel rail, use new O-ring(s)
   • EGR pipe
   • Vacuum hoses and the PCV hose assembly
   • Alternator wiring harness connector
8. Reposition the engine control wiring harness and install the brackets and clips.
9. Install or connect the following:
   • IAC motor and the TP sensor connectors
   • Vacuum hose to the throttle body
   • MAP and the IAT sensor connectors
   • Accelerator cable in the bracket and connect it to the throttle body
   • Breather hose and the air intake hose
   • Vacuum reservoir, if equipped
   • Negative battery cable
10. Refill the engine with coolant.

2.4L (4G64) ENGINE

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Relieve the fuel system pressure.
3. Remove the battery.
4. Drain the engine coolant.
5. Remove or disconnect the following:
   • Accelerator cable
   • Air intake hose
   • Ignition coil and the module wiring connectors
   • MAP sensor
   • Condenser
   • TP sensor and the IAC motor connectors
   • HO2S sensor connector
   • CKP sensor connector
   • Air conditioning compressor connector
   • Engine control wiring harness bracket and position the harness out of the way
   • Vacuum hoses, label for reference
   • Spark plug wires from the ignition coil
   • Fuel lines from the fuel rail
   • Heater hoses
   • Fuel rail assembly
   • Ignition coil and module
   • EGR valve assembly
   • Intake manifold stay and the engine hanger
   • Intake manifold

     Fig. 5: Intake manifold and related components — Eclipse and Galant 2.4L (4G64) engines

   To install:

6. Install or connect the following:
   • Intake manifold. Torque the intake manifold bolts to 15 ft. lbs. (20 Nm).
   • Intake manifold stay and the engine hanger. Torque the mounting bolts to 19–24 ft. lbs. (26–33 Nm).
   • EGR assembly
   • Ignition coil and module
   • Fuel rail and insulators and reconnect the high-pressure fuel hose
   • Heater hoses and fuel lines
   • Spark plug wires to the coil towers
   • Vacuum hoses
   • Engine harness in the proper position
   • MAP sensor
   • TP sensor and the IAC motor connectors
   • HO2S
   • Ignition condenser
   • Accelerator cable, adjust
   • Battery
7. Refill the engine with coolant.

Galant

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Relieve the fuel system pressure.
3. Disconnect battery negative cable.
4. Drain the cooling system.
5. Remove or disconnect the following:
   • Accelerator cable
   • Air intake hose
   • Coolant hose from the throttle housing
   • Vacuum lines, label for reference
   • High pressure fuel line and fuel return hose
   • Throttle control cable brackets
6. Disconnect the following:
   • ECT sensor and gauge sender
   • IAC motor
   • EGR temperature sensor
   • Ignition coil
   • Knock sensor
   • HO2S sensor
   • TP sensor
   • Distributor (if equipped)
   • air conditioning temperature sensor
   • Ignition power transistor
   • Fuel injectors
7. Remove or disconnect the following:
   • Spark plug wires
   • Intake manifold stay bracket
   • Intake manifold mounting bolts and remove the intake manifold assembly

   To install:

8. Clean all gasket material from the cylinder head intake mounting surface and intake manifold assembly.
9. Install or connect the following:
   • Intake manifold, using a new gasket. Torque the manifold in a crisscross pattern, starting from the inside and working outwards to 15 ft. lbs. (20 Nm).
   • Fuel injectors, fuel rail and pressure regulator to the engine. Torque the retaining bolts to 48 inch lbs. (6 Nm).
   • Intake manifold brace bracket and tighten bolts to 21 ft. lbs. (29 Nm)
   • Spark plug wires
10. Connect the following:
    • ECT sensor and gauge sender
    • IAC motor
    • EGR temperature sensor
    • Ignition coil
    • Knock sensor
    • HO2S sensor
    • TP sensor
    • Distributor (if equipped)
    • air conditioning temperature sensor
    • Ignition power transistor
    • Fuel injectors
11. Install or connect the following:
    • Throttle control cable brackets
    • High pressure fuel line and fuel return hose
    • Vacuum lines
    • Coolant hoses
    • Accelerator cable
    • Air intake hose
12. Fill the system with coolant.
13. Connect the negative battery cable.

Mirage

1.5L (4G15) ENGINE

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Relieve the fuel system pressure.
3. Remove or disconnect the following:
   • Battery negative cable and drain the cooling system
   • Upper radiator hose, heater hose and water bypass hose
   • Thermostat housing from intake manifold
   • Accelerator cable, breather hose and air intake hose
   • Vacuum hoses, label for reference
   • Throttle body assembly
   • High pressure fuel line and the fuel return hose
4. Disconnect the following:
   • HO2S sensor
   • ECT sensor
   • IAC motor
   • IAT sensor
   • Distributor (if equipped)
   • EGR temperature sensor
5. Remove or disconnect the following:
   • Spark plug wires
   • Fuel rail, fuel injectors, pressure regulator and insulators
   • EGR valve from the intake manifold
   • Intake manifold support bracket and remove the engine mount support bracket
   • Intake manifold mounting bolts and remove the intake manifold assembly

   To install:

6. Clean all gasket material from the cylinder head intake mounting surface and intake manifold assembly.
7. Install or connect the following:
   • Intake manifold gasket, using a new gasket. Torque the manifold in a crisscross pattern, starting from the inside and working outwards to 13 ft. lbs. (18 Nm).
   • Intake manifold support bracket and tighten the mounting bolts to 16 ft. lbs. (22 Nm)
   • Engine mount support bracket and tighten the mounting bolts to 26 ft. lbs. (36 Nm)
   • EGR valve and tighten the mounting bolts to 15 ft. lbs. (21 Nm)
   • Install the fuel rail, fuel injectors and pressure regulator to the engine, using new insulators and O-rings. Torque the retaining bolts to 84–108 inch lbs. (10–13 Nm).
   • Spark plug wires
8. Connect the following:
   • HO2S sensor
   • ECT sensor
   • IAC motor
   • IAT sensor
   • Distributor (if equipped)
   • EGR temperature sensor
9. Install or connect the following:
   • Fuel feed and return lines
   • Throttle body assembly
   • Vacuum hoses and pipes as necessary, including the brake booster vacuum line
   • Accelerator cable
   • Breather and air intake hose
   • Thermostat housing to the intake manifold and tighten the mounting bolts to 13 ft. lbs. (18 Nm)
   • Upper radiator hose, heater hose and water bypass hose
10. Fill the system with coolant.
11. Connect the negative battery cable.

    Fig. 6: Exploded view of the intake and exhaust manifold mounting — Mirage 1.5L (4G15) engine

1.8L (4G93) ENGINE

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Relieve the fuel system pressure.
3. Remove or disconnect the following:
   • Battery negative cable and drain the cooling system
   • Accelerator cable and the air intake hose
4. Disconnect the following:
   • HO2S sensor
   • ECT sensor
   • IAC motor
   • EGR temperature sensor
   • TP sensor
   • Oil pressure switch
   • Distributor (if equipped)
   • Fuel injectors
5. Label and remove all vacuum hoses.
6. Remove or disconnect the following:
   • Upper radiator hose, heater hose and water bypass hose
   • High pressure fuel line and the fuel return hose
   • Fuel rail, fuel injectors, pressure regulator and insulators
   • Intake manifold support bracket
   • Thermostat housing, if necessary for clearance
   • Intake manifold mounting bolts/nuts and remove the intake manifold assembly

   To install:

7. Clean all gasket material from the cylinder head intake mounting surface and intake manifold assembly.
8. Install or connect the following:
   • Intake manifold, using a new gasket. Torque the manifold in a crisscross pattern, starting from the inside and working outwards to 14 ft. lbs. (20 Nm).
   • Thermostat housing
   • Intake manifold brace bracket
   • Fuel rail, fuel injectors and pressure regulator to the engine. Torque the retaining bolts to 108 inch lbs. (12 Nm).
   • Fuel feed and return lines
   • Upper radiator hose, heater hose and water bypass hoses
   • Vacuum hoses
9. Connect the following:
   • HO2S sensor
   • ECT sensor
   • IAC motor
   • EGR temperature sensor
   • TP sensor
   • Oil pressure switch
   • Distributor (if equipped)
   • Fuel injectors
10. Connect and adjust the accelerator cable and install the air intake hose.
11. Fill the system with coolant.
12. Connect the negative battery cable.