Before you start on the intake manifold, make sure fuel system pressure is released and that the surroundings are well ventilated and away from anything that could cause ignition. After unlinking the negative cable from the auxiliary jumper terminal, take the air inlet resonator out. Clear out the fuel system pressure by following the procedure and afterwards disconnect the fuel supply line quick connect from the
Fuel Rail assembly, holding shop towels around the line to catch any leaking gasoline. Loosen the attaching screws of the fuel rail assembly and use something to cover the injector holes, making sure not to set the
Fuel Injectors on their tips. Remove the connectors for the accelerator and speed control, for the Idle Air Control (IAC),
Throttle Position Sensor (TPS) and finally the intake air connector. You should also unplug the leak detection pump and PCV hoses, the
Knock Sensor's electrical connection and the wiring harness at the tab on the intake manifold. Take out the transaxle to
Throttle Body support bracket bolts and release the bolt at the rear transaxle end. Unscrew the bolts for the
EGR Tube at the valve and the intake manifold, remove the old gaskets and lift out the intake manifold from its spot on the inlet water tube support. Next, get rid of the intake manifold fasteners and washer assemblies to pull out the manifold. Once installation begins, change all O-ring seals and take out the old manifold screws and their washers, replacing them with new ones. Install the fresh O-ring seals and lock the bolts with a torque of 12 Nm (105 in. lbs.) as directed. After taking off the cover on the fuel injector holes and cleaning them, put the fuel rail assembly into the intake manifold and tighten the screws to 23 Nm (200 in. lbs.). Join the PCV and brake booster hoses, look for damage in the quick connect fittings, apply a light layer of engine oil to the tube and connect the fuel supply hose to the fuel rail assembly, verifying the connection with a pull on the connector. After setting the throttle body, torque its fasteners to 22 Nm (200 in. lbs.); then, fit the transaxle to the throttle body bracket by tightening the screw at the throttle body first and then at the bracket at the transaxle, to 12 Nm (105 in. lbs.). Attach the MAP, intake air temperature sensor, knock sensor and starter relay wiring connectors together. Wrap the wiring harness around the intake manifold tab and link the IAC motor and TPS connectors to the sensors. At this point, put the vacuum hoses on the throttle body and join the accelerator and speed control cables to their bracket and throttle lever. Once you've installed the new EGR gaskets, gently fit the EGR tube onto the valve and manifold and tighten the fasteners at the EGR valve to 11 Nm (95 in. lbs.) and then those at the manifold to 11 Nm (95 in. lbs.). After this, attach the negative cable to the auxiliary jumper terminal and then use the DRB scan tool for the ASD Fuel System Test, turning on the ASD relay for either 7 minutes or until you shut down the test by other means or switch the ignition off.