Protege 1999-2000

Intake Manifold

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Removal & Installation



1.6L (Zm) Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Fuel hoses from the fuel rail
     
    Fuel injector electrical connectors
     
    Fuel rail with the injectors connected
     
    Components in the order illustrated

    Click image to see an enlarged view

    Fig. Exploded view of the intake manifold, illustrating the removal and installation components with tightening values-1.6L engine

     

  6.  

To install:

  1. Clean all gasket mating surfaces.
    NOTE
    Be sure that the convex side of the intake manifold gasket is facing the manifold side, as shown.



    Click image to see an enlarged view

    Fig. Cross-sectional view of the intake manifold gasket-1.6L (ZM) engines

  2.  
  3. Install or connect the following:

    Intake manifold using a new gasket, make sure the convex side of the gasket faces the manifold. Torque the bolts to 14-18 ft. lbs. (19-25 Nm).
     
    Components in the reverse order of the removal sequence
     
    Fuel rail. Tighten the bolts to 14-18 ft. lbs. (19-25 Nm).
     
    Fuel lines and electrical connectors to the fuel rail
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Run the engine and check for leaks.
  8.  

 
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