Intake manifold ASSY (FA20)
Components Removal / installation
INTAKE / EXHAUST
INTAKE MANIFOLD ASSY (FA20)
EXPLODED VIEW
REMOVAL
1. Fuel spill prevention procedure (Refer to 
)
)2. Disconnection of the battery ground terminal (Refer to )
)3. Removal of air cleaner case SUB-ASSY (Refer to )
)
4. Disconnection of throttle body ASSY (with motor)
(1) Remove the 4 bolts, and remove the throttle body ASSY (with motor).
5. Removal of injector driver (Refer to )
)6. Removal of intake manifold protector (bank 2 side) (Refer to )
)7. Removal of intake manifold protector (bank 1 side) (Refer to )
)8. Disconnection of fuel hose (Refer to )
)
9. Disconnection of fuel delivery pipe SUB-ASSY
(1) Remove the bolt and disconnect the fuel delivery pipe SUB-ASSY.
(2) Disconnect fuel vapor feed hose NO.2 and the purge hose, and remove the fuel delivery pipe SUB-ASSY.
10. Removal of engine cover SUB-ASSY NO. 1 (when there is air conditioning)
(1) Release the 3 tabs, and remove the engine cover SUB-ASSY NO.1.
NOTE:
Release the tabs from the front side of the vehicle.
11. Disconnection of union-to-check valve hose (transmission M/T) (Refer to )
)
12. Disconnection of ventilation hose
(1) Disconnect the ventilation hose.
13. Intake manifold removal
(1) Disconnect the connector for air pressure sensor ASSY.
(2) Disconnect the connector for the purge control solenoid valve.
(3) Release the 5 clamps and disconnect the battery cable.
(4) Release the clamp and disconnect the wiring harness.
(5) Release the two clamps and disconnect the four connectors to disconnect the wiring harness.
Captions in illustration
| *a |
LH side |
| *b |
RH side |
(6) Disconnect the fuel pump connector.
DISASSEMBLY
1. Removal of air pressure sensor ASSY
(1) Remove the bolt and remove the air pressure sensor ASSY from the intake manifold.
(2) Remove the O-ring from the air pressure sensor ASSY.
2. Removal of purge control solenoid valve
(1) Disconnect the fuel vapor feed hose NO.1 from the intake manifold.
(2) Remove the nut, and remove the purge control solenoid valve from the intake manifold.
3. Cap removal (transmission A/T)
(1) Slide the clamp and remove the cap from the intake manifold.
4. Fuel delivery pipe removal (bank 2 side)
(1) Disconnect the fuel delivery pipe NO. 3 from the fuel delivery pipe (bank 2 side).
CAUTION:
·Before starting the work, remove any foreign matter such as dirt from the fuel delivery pipe NO.3 connector.
·Because the fuel delivery pipe NO.3 connector and the pipe are sealed by an O-ring, be careful not to damage or let foreign matter get stuck to the connection.
·Always perform this removal / installation by hand. Do not use any tools.
·Do not bend, fold, or turn the nylon tubes with excessive force.
·If the fuel delivery pipe NO.3 connector and pipe are stuck, first push and pull to release them, then pull it out.
·Check that top hats are not removed.
·After disconnecting fuel delivery pipe NO.3, protect the connection part with a plastic bag or something similar.
·Because the fuel delivery pipe NO.3 connector and the pipe are sealed by an O-ring, be careful not to damage or let foreign matter get stuck to the connection.
·Always perform this removal / installation by hand. Do not use any tools.
·Do not bend, fold, or turn the nylon tubes with excessive force.
·If the fuel delivery pipe NO.3 connector and pipe are stuck, first push and pull to release them, then pull it out.
·Check that top hats are not removed.
·After disconnecting fuel delivery pipe NO.3, protect the connection part with a plastic bag or something similar.
Captions in illustration
| *1 |
Retainer |
*2 |
Fuel delivery pipe NO.3 connector |
| *3 |
Nylon tube |
*4 |
O-ring |
| *5 |
Pipe |
*6 |
Top hat |
(2) Remove the 2 bolts and remove the fuel delivery pipe (bank 2 side) from the intake manifold.
5. Fuel delivery pipe removal (bank 1 side)
(1) Disconnect the fuel delivery pipe NO. 3 from the fuel delivery pipe (bank 1 side).
CAUTION:
·Before starting the work, remove any foreign matter such as dirt from the fuel delivery pipe NO.3 connector.
·Because the fuel delivery pipe NO.3 connector and the pipe are sealed by an O-ring, be careful not to damage or let foreign matter get stuck to the connection.
·Always perform this removal / installation by hand. Do not use any tools.
·Do not bend, fold, or turn the nylon tubes with excessive force.
·If the fuel delivery pipe NO.3 connector and pipe are stuck, first push and pull to release them, then pull it out.
·Check that top hats are not removed.
·After disconnecting fuel delivery pipe NO.3, protect the connection part with a plastic bag or something similar.
·Because the fuel delivery pipe NO.3 connector and the pipe are sealed by an O-ring, be careful not to damage or let foreign matter get stuck to the connection.
·Always perform this removal / installation by hand. Do not use any tools.
·Do not bend, fold, or turn the nylon tubes with excessive force.
·If the fuel delivery pipe NO.3 connector and pipe are stuck, first push and pull to release them, then pull it out.
·Check that top hats are not removed.
·After disconnecting fuel delivery pipe NO.3, protect the connection part with a plastic bag or something similar.
Captions in illustration
| *1 |
Retainer |
*2 |
Fuel delivery pipe NO.3 connector |
| *3 |
Nylon tube |
*4 |
O-ring |
| *5 |
Pipe |
*6 |
Top hat |
(2) Remove the 2 bolts and remove the fuel delivery pipe (bank 1 side) from the intake manifold.
6. Fuel delivery pipe NO.3 removal
(1) Remove the 3 clamps, and remove the fuel delivery pipe NO.3 from the intake manifold.
ASSEMBLY
1. Fuel delivery pipe NO.3 installation
(1) With the 3 clamps, install the fuel delivery pipe NO.3 on the intake manifold.
2. Fuel delivery pipe installation (bank 2 side)
(1) Apply gasoline to 2 new O-rings and install them to the fuel injector ASSY.
CAUTION:
Make sure there is no damage to or foreign matter in O-ring grooves of the injector.
(2) With the fuel injector ASSY installed on the fuel delivery pipe (bank 2 side), install it to the intake manifold.
CAUTION:
·Be careful not to twist the O-ring.
·After it is attached to the fuel delivery pipe (bank 2 side), confirm that it can be rotated relatively lightly. If it cannot be rotated, remove the injector and repeat the work after replacing the O-rings with new ones.
·After it is attached to the fuel delivery pipe (bank 2 side), confirm that it can be rotated relatively lightly. If it cannot be rotated, remove the injector and repeat the work after replacing the O-rings with new ones.
(3) With 2 bolts, install the fuel delivery pipe (bank 2 side) to the intake manifold.
Standard value:
Standard value:
Tightening torque=19N·m
{
194kgf·cm}
{14ft·lbf}
(4) Align the axis of the fuel delivery pipe NO.3 connector and the axis of the pipe, connect them, and push the retainer until you hear the click.
CAUTION:
·Before starting the work, check that there is no damage to or foreign material on the fuel delivery pipe NO.3 connector and the pipe connection.
·After connecting fuel delivery pipe NO.3, check that the fuel delivery pipe NO.3 connecter and the pipe are securely attached.
·After connecting fuel delivery pipe NO.3, check that the fuel delivery pipe NO.3 connecter and the pipe are securely attached.
3. Fuel delivery pipe removal (bank 1 side)
(1) Apply gasoline to 2 new O-rings and install them to the fuel injector ASSY.
CAUTION:
Make sure there is no damage to or foreign matter in O-ring grooves of the injector.
(2) With the fuel injector ASSY installed on the fuel delivery pipe (bank 1 side), install it to the intake manifold.
CAUTION:
·Be careful not to twist the O-ring.
·After it is attached to the fuel delivery pipe (bank 1 side), confirm that it can be rotated relatively lightly. If it cannot be rotated, remove the injector and repeat the work after replacing the O-rings with new ones.
·After it is attached to the fuel delivery pipe (bank 1 side), confirm that it can be rotated relatively lightly. If it cannot be rotated, remove the injector and repeat the work after replacing the O-rings with new ones.
(3) With 2 bolts, install the fuel delivery pipe (bank 1 side) to the intake manifold.
Standard value:
Standard value:
Tightening torque=19N·m
{
194kgf·cm}
{14ft·lbf}
(4) Align the axis of the fuel delivery pipe NO.3 connector and the axis of the pipe, connect them, and push the retainer until you hear the click.
CAUTION:
·Before starting the work, check that there is no damage to or foreign material on the fuel delivery pipe NO.3 connector and the pipe connection.
·After connecting fuel delivery pipe NO.3, check that the fuel delivery pipe NO.3 connecter and the pipe are securely attached.
·After connecting fuel delivery pipe NO.3, check that the fuel delivery pipe NO.3 connecter and the pipe are securely attached.
4. Cap installation (transmission A/T)
(1) Install the cap to the intake manifold.
5. Installation of purge control solenoid valve
(1) Connect the fuel vapor feed hose NO.1 to the intake manifold.
(2) Using the nut, install the purge control solenoid valve to the intake manifold.
Standard value:
Standard value:
Tightening torque=6.4N·m
{
65kgf·cm}
{4.7ft·lbf}
6. Installation of air pressure sensor ASSY
(1) Attach a new O-ring to the air pressure sensor ASSY.
(2) Apply engine oil to the O-ring.
(3) With a bolt, install the air pressure sensor ASSY to the intake manifold.
Standard value:
Standard value:
Tightening torque=4.0N·m
{
41kgf·cm}
{3.0ft·lbf}
INSTALLATION
1. Intake manifold installation
(1) Install two new gaskets to the intake manifold.
(2) Install the intake manifold with the six bolts.
Standard value:
Standard value:
Tightening torque=25N·m
{
255kgf·cm}
{18.4ft·lbf}
(3) Engage the 2 clamps and the 4 connectors, and connect the wiring harness.
(4) Connect the fuel pump connector.
(5) Engage the clamp to connect the wiring harness.
(6) Engage the 5 clamps and connect the battery cable.
(7) Connect the connector for the purge control solenoid valve.
(8) Connect the connector for air pressure sensor ASSY.
2. Ventilation hose connection
(1) Connect the ventilation hose.
3. Union to check valve hose connection (transmission M/T)
(1) With a hose clamp, connect the union to check valve hose to the intake manifold.
4. Engine cover SUB-ASSY NO. 1 installation (when there is air conditioning)
(1) Fit in the 3 tabs, and install the engine cover SUB-ASSY NO.1.
5. Fuel delivery pipe SUB-ASSY connection
(1) Connect the fuel vapor feed hose NO.2 and the purge hose.
(2) With a bolt, install the fuel delivery pipe SUB-ASSY.
Standard value:
Standard value:
Tightening torque=6.4N·m
{
65kgf·cm}
{4.7ft·lbf}
6. Fuel hose connection (Refer to )
)7. Installation of intake manifold protector (bank 1 side) (Refer to )
)8. Installation of intake manifold protector (bank 2 side) (Refer to )
)9. Installation of injector driver (Refer to )
)10. Throttle body ASSY (with motor) connection
(1) Install a new gasket to the intake manifold.
(2) With 4 bolts, connect the throttle body ASSY (with motor) to the intake manifold.
Standard value:
Standard value:
Tightening torque=8.0N·m
{
82kgf·cm}
{5.9ft·lbf}
11. Installation of air cleaner case SUB-ASSY (Refer to )
)12. Connection of the battery ground terminal
Standard value:
Standard value:
Tightening torque=6.0N·m
{
61kgf·cm}
{4.4ft·lbf}
13. Function inspection of throttle body ASSY (with motor) (Refer to )
)