INTAKE MANIFOLD
Fuel Injection (Fuel Systems)
3. Intake Manifold
S155034
NOTE:
Do not disconnect power steering hose.
A: REMOVAL
S155034A18
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1)   Release fuel pressure. <Ref. to FU(SOHC)-52, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.>
2)  Open fuel flap lid, and remove fuel filler cap.
3)   Disconnect battery ground cable.
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(4) Remove bolts which install power steering pump bracket.
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4)   Remove air intake duct and air cleaner assem­bly. <Ref. to IN(SOHC)-8, REMOVAL, Air Intake Duct.> and <Ref. to IN(SOHC)-7, REMOVAL , Air Cleaner Case.>
5)   Disconnect accelerator cable (A).
6)   Disconnect cruise control cable (B). (With cruise control model)
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(5) Disconnect connector from power steering pump switch.
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7) Remove power steering pump and tank from brackets.
(1)   Remove resonator chamber. <Ref. to IN(SOHC)-9, REMOVAL, Resonator Chamber.>
(2)   Remove front side V-belt. <Ref. to ME(SOHC)-42, REMOVAL, V-belt.>
(3)   Remove bolts which hold power steering pipes brackets onto intake manifold.
(6) Place power steering pump and tank on the right side wheel apron.
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8) Disconnect spark plug cords from spark plugs. FU(SOHC)-15
INTAKE MANIFOLD
Fuel Injection (Fuel Systems)
9) Disconnect PCV hose from intake manifold.
13) Disconnect connectors from engine coolant temperature sensor.
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10) Disconnect engine coolant hose from throttle body.
14) Disconnect knock sensor connector.
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11) Disconnect brake booster hose.
15) Disconnect connector from crankshaft position sensor.
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12) Remove air cleaner case stay RH and engine harness bracket, and disconnect engine harness connectors from bulkhead harness connectors.
16) Disconnect connector from oil pressure switch.
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FU(SOHC)-16
INTAKE MANIFOLD
Fuel Injection (Fuel Systems)
17) Disconnect connector from camshaft position sensor.
20) Remove intake manifold.
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18) Disconnect fuel hoses from fuel pipes.
WARNING:
-  Do not spill fuel.
-  Catch fuel from hoses in a container or cloth.
B: INSTALLATION
S155034A11
1) Install intake manifold onto cylinder heads.
NOTE:
Always use new gaskets.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
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(A)     Fuel delivery hose
(B)     Return hose
(C)    Evaporation hose
19) Remove bolts which hold intake manifold onto cylinder heads.
2) Connect fuel hoses.
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(A)     Fuel delivery hose
(B)     Return hose
(C)    Evaporation hose
FU(SOHC)-17
INTAKE MANIFOLD
Fuel Injection (Fuel Systems)
3) Connect connector to camshaft position sensor. 7) Connect connectors to engine coolant tempera­ture sensor.
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4) Connect connector to oil pressure switch.
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8) Install air cleaner case stay RH and engine har­ness bracket, and connect engine harness con­nectors to bulkhead connectors.
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5) Connect connector to crankshaft position sen­sor.
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9) Connect brake booster hose.
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6) Connect knock sensor connector.
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10) Connect engine coolant hose to throttle body.
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FU(SOHC)-18
INTAKE MANIFOLD
Fuel Injection (Fuel Systems)
11) Connect PCV hose to intake manifold.
(3) Install power steering pipe brackets onto right side intake manifold.
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12)  Connect spark plug cords to spark plugs.
13)   Install power steering pump on brackets.
(1) Connect terminal to power steering pump switch.
(4)   Install front side V-belt. <Ref. to ME(SOHC)-42, INSTALLATION, V-belt.>
(5)   Install resonator chamber.
Tightening torque:
33 Nm (3.4 kgf-m, 24.6 ft-lb)
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(2) Tighten bolts which install power steering pump on bracket.
Tightening torque:
20.1 Nm (2.05 kgf-m, 14.8 ft-lb)
14)  Connect accelerator cable (A).
15)  Connect cruise control cable (B). (With cruise control models)
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16) Install air intake duct and air cleaner assem­bly. <Ref. to IN(SOHC)-8, REMOVAL, Air Intake Duct.> and <Ref. to IN(SOHC)-7, INSTALLATION, Air Cleaner Case.>
FU(SOHC)-19
INTAKE MANIFOLD
Fuel Injection (Fuel Systems)
17) Connect connector to fuel pump relay.
3) Remove ignition coil and ignitor assembly.
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18) Connect battery ground cable.
4) Disconnect connector from intake air tempera­ture and pressure sensor.
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C: DISASSEMBLY
S155034A06
5) Remove intake air temperature and pressure sensor from intake manifold.
1) Disconnect engine ground terminal from intake manifold.
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6) Disconnect connectors from throttle position sensor and idle air control solenoid valve.
2) Disconnect connector from ignition coil and ignitor assembly.
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FU(SOHC)-20
INTAKE MANIFOLD
Fuel Injection (Fuel Systems)
7) Disconnect air by-pass hose from throttle body.
12) Disconnect pressure regulator vacuum hose from intake manifold.
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8) Remove throttle body.
13) Disconnect connectors from fuel injectors.
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9)   Disconnect connector from air assist injector solenoid valve.
10)   Disconnect air by-pass hoses from air assist solenoid valve.
14) Disconnect connector from purge control sole­noid valve.
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15)   Disconnect air by-pass hose from purge con­trol solenoid valve.
16)   Remove harness bands (A) and harness bracket (B) which hold engine harness onto intake manifold.
11) Remove air assist injector solenoid valve from intake manifold.
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FU(SOHC)-21
INTAKE MANIFOLD
Fuel Injection (Fuel Systems)
17)   Remove engine harness from intake manifold.
18)   Remove purge control solenoid valve.
22) Remove fuel injectors.
(1) Remove fuel injector securing clip.
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19) Remove bolt which installs injector pipe on intake manifold as shown in figure.
(2) Remove fuel injector while lifting up fuel injector pipe.
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20) Remove bolt which installs injector pipe on intake manifold.
23) Disconnect air by-pass hoses from intake manifold.
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21) Remove two bolts which hold fuel pipes on the left side of intake manifold.
24) Loosen clamp which holds front left side fuel hose to injector pipe and remove the pipe from fuel hose.
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FU(SOHC)-22
INTAKE MANIFOLD
Fuel Injection (Fuel Systems)
25) Loosen clamp which holds front right side fuel hose to injector pipe and remove the pipe from fuel hose.
2) Tighten bolt which installs fuel pipes on intake manifold.
Tightening torque:
4.9 Nm (0.5 kgf-m, 3.6 ft-lb)
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26) Remove fuel injector pipe.
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3) Connect right side fuel hose to injector pipe, and tighten clamp screw.
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27) Remove bolt which installs fuel pipes on intake manifold.
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4) Install fuel injector pipe.
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28) Remove fuel pipe assembly and pressure regulator, from intake manifold.
5) Connect left side fuel hose to injector pipe, and tighten clamp screw.
D: ASSEMBLY
S155034A02
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1) Install fuel pipe assembly and pressure regulator, etc. to intake manifold.
FU(SOHC)-23
INTAKE MANIFOLD
Fuel Injection (Fuel Systems)
6) Connect air assist hoses.
8) Tighten bolt which installs injector pipe on intake manifold.
Tightening torque:
4.9 Nm (0.50 kgf-m, 3.6 ft-lb)
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7) Install fuel injectors.
NOTE:
Always use new O-rings.
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9) Tighten two bolts which install fuel pipes on the left side of intake manifold.
Tightening torque:
4.9 Nm (0.50 kgf-m, 3.6 ft-lb)
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(A)    O-ring
(B)     Fuel injector
NOTE:
Do not forget to install the fuel injector securing
clip.
10) Tighten bolt which installs injector pipe on intake manifold.
Tightening torque:
4.9 Nm (0.50 kgf-m, 3.6 ft-lb)
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FU(SOHC)-24
INTAKE MANIFOLD
Fuel Injection (Fuel Systems)
11) Install purge control solenoid valve.
Tightening torque:
16 Nm (1.6 kgf-m, 12 ft-lb)
16) Connect pressure regulator vacuum hose to intake manifold.
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17) Install air assist injector solenoid valve to bracket.
Tightening torque:
4.9 Nm (0.50 kgf-m, 3.6 ft-lb)
12) Connect hoses to purge control solenoid valve.
CAUTION:
Carefully connect the evaporation hoses.
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18) Connect air by-pass hoses to air assist sole­noid valve.
13)   Install engine harness onto intake manifold.
14)  Connect connectors to fuel injectors and purge control solenoid valve.
15)   Hold engine harness by harness band (A) and harness bracket (B).
Tightening torque:
16 Nm (1.6 kgf-m, 12 ft-lb)
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19) Connect connector to air assist solenoid valve.
FU(SOHC)-25
INTAKE MANIFOLD
Fuel Injection (Fuel Systems)
20) Install throttle body to intake manifold.
NOTE:
Replace gasket with a new one.
Tightening torque:
22 Nm (2.2 kgf-m, 15.9 ft-lb)
23) Install intake air temperature and pressure sensor.
Tightening torque:
3.4 Nm (0.35 kgf-m, 2.5 ft-lb)
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NOTE:
Replace O-ring with a new one.
21) Connect connector to throttle position sensor and idle air control solenoid valve.
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24)  Connect connector to intake air temperature and pressure sensor.
25)   Install ignition coil and ignitor assembly.
22) Connect air by-pass hose to throttle body.
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FU(SOHC)-26
INTAKE MANIFOLD
Fuel Injection (Fuel Systems)
26)  Connect connector to ignition coil and ignitor assembly.
27)   Install engine ground terminal to intake mani­fold.
Tightening torque:
19 Nm (1.9 kgf-m, 13.7 ft-lb)
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E: INSPECTION
S155034A10
Make sure the fuel pipe and fuel hoses are not cracked and that connections are tight.
FU(SOHC)-27