Removal and installation of the intake manifold of the K4M engine

Removing and Fitting the K4M Engine Intake Manifold

We remove the intake silencer.

We remove the air filter housing.

We remove the throttle body hose.

Removing the intake manifold
Fig. 1. Removing the K4M engine intake manifold: 1 — throttle drive cable; 2 — wiring harness connector to the ignition coils; 3 — wiring harness connector to the air temperature sensor; 4 — wiring harness connector to the intake air pressure sensor; 5 — intake manifold
  1. We disconnect the throttle drive cable 1 (Figure 1) from the intake manifold 5.
  2. We disconnect the connectors 2 from the ignition coils.
  3. We disconnect the connector 3 from the engine temperature sensor.
  4. We disconnect the connector 4 from the intake air pressure sensor.
Intake manifold retaining bolts
Fig. 2. Removing the K4M engine intake manifold: 1–7 — intake manifold retaining bolts
  1. Using an 8 mm socket, we unscrew the seven bolts (Figure 2) and remove the intake manifold complete with the air temperature sensor and the intake air pressure sensor.

Fitting the intake manifold

Important! All gaskets must be replaced.

  1. Before fitting the intake manifold, fit a new gasket onto the intake manifold.
  2. We fit the intake manifold to the vehicle.
  3. We fit and tighten the retaining bolts in the sequence shown in Figure 2. Bolt tightening torque: 9 N·m (0.9 kgf·m) (8 mm socket, extension, handle, torque wrench).
  4. We connect connector 4 (Figure 1) to the intake air pressure sensor.
  5. We connect connector 3 to the air temperature sensor.
  6. We connect connectors 2 to the ignition coils.
  7. We connect the throttle drive cable 1 to the intake manifold 5.
  8. We fit the throttle body hose, the air filter housing and the intake silencer.
  9. Using a 10 mm spanner, we connect the negative terminal to the battery.