AutoZone 1999 Toyota Truck RAV4 2WD 2.0L EFI DOHC 4cyl | Repair Guides | Engine Mechanical | Engine Mechanical Components | Intake Manifold | AutoZone.com

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    1999 Toyota Truck RAV4 2WD 2.0L EFI DOHC 4cyl

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    Mazda RX-8 2004-06

    Intake Manifold

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    Removal & Installation



    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Relieve the fuel system pressure.
    4.  
    5. Drain the cooling system.
    6.  
    7. Remove the engine and transmission assembly.
    8.  
    9. Remove or disconnect the following:

      Air hose
       
      Air cleaner cover
       
      Variable Fresh Air Duct (VFAD) solenoid valve on high output engines
       
      Vacuum chamber on high output engines
       
      Air cleaner case
       
      Throttle body
       
      Upper extension manifold
       
      Lower extension manifold on high output engines
       
      Oil filler pipe
       
      Air Injection Reactor (AIR) solenoid valve
       
      Secondary Shutter Valve (SSV) solenoid
       
      Variable Dynamic Effect Intake (VDI) solenoid valve.
       
      Air cleaner insulator
       
      Auxiliary Port Valve (APV) bracket and motor on high output engines
       
      Fresh air intake duct
       
      Fuel distributors
       
      Intake manifold and discard the gasket

      Click image to see an enlarged view

      Fig. Exploded view of the air intake system-RX-8



      Click image to see an enlarged view

      Fig. Exploded view of the intake manifold-RX-8



      Click image to see an enlarged view

      Fig. Applying oil to the APV valves-RX-8



      Click image to see an enlarged view

      Fig. Intake manifold tightening sequence-RX-8

       

    10.  

    To install:

    1. Clean all gasket mating surfaces.
    2.  
    3. Apply clean oil to the APV valves as shown
    4.  
    5. Install or connect the following:

      Intake manifold using a new gasket in the sequence shown. Torque the bolts to 14-19 ft. lbs. (19-26 Nm). Retighten bolt no. 1.
       
      Fuel distributors and torque the bolts to 14-19 ft. lbs. (19-26 Nm)
       
      Fresh air intake duct and torque the bolts to 69-96 inch lbs. (8-11 Nm)
       
      Auxiliary Port Valve (APV) bracket and motor on high output engines
       
      Air cleaner insulator and torque the bolts to 69-96 inch lbs. (8-11 Nm)
       
      Variable Dynamic Effect Intake (VDI) solenoid valve.
       
      Secondary Shutter Valve (SSV) solenoid
       
      Air Injection Reactor (AIR) solenoid valve
       
      Oil filler pipe and torque the bolts to 79-112 inch lbs. (9-13 Nm)
       
      Lower extension manifold on high output engines and torque the bolts to 79-112 inch lbs. (9-13 Nm)
       
      Upper extension manifold and torque the bolts to 69-96 inch lbs. (8-11 Nm)
       
      Throttle body and torque the bolts to 69-96 inch lbs. (8-11 Nm)
       
      Air cleaner case
       
      Vacuum chamber on high output engines
       
      Variable Fresh Air Duct (VFAD) solenoid valve on high output engines
       
      Air cleaner cover
       
      Air hose
       
      Engine and transmission assembly
       
      Negative battery cable
       

    6.  
    7. Fill the cooling system.
    8.  
    9. On models with dynamic suspension, perform the steering angle sensor initialization procedure.
    10.  
    11. Run the engine and check for leaks.
    12.  

     
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