Tracker 4x4 L4-1.6L SOHC TBI (1994)
Intake Manifold: Service and Repair
Fig. 4 Throttle Body & Intake Manifold
1. Relieve fuel system pressure.
2. Disconnect battery ground cable.
3. Drain coolant from cooling system.
4. Remove air intake case from throttle body assembly.
5. Remove accelerator cable and kickdown cable from throttle body by sliding cable clip at lever.
6. Disconnect electrical connections at throttle body and intake manifold.
7. Disconnect evaporative emission solenoid purge valve electrical connector.
8. Disconnect vacuum lines from throttle body and throttle opener.
9. Disconnect the brake booster supply hose.
10. Disconnect coolant hose and air hose from ISC solenoid valve.
11. Remove fuel feed pipe from throttle body and intake manifold.
12. Disconnect fuel return hose from pressure regulator.
13. Remove throttle body from intake manifold, Fig. 4.
14. Remove vacuum lines from manifold.
15. Remove coolant hose from thermostat housing, heater inlet and coolant bypass hose from intake manifold.
16. Remove intake manifold from cylinder head.
17. Reverse procedure to install, noting the following:
a. Tighten intake manifold, throttle body and harness retaining clamp bolts to specifications.
b. Before installing any component, ensure gasket is properly seated.
c. Prior to installing fuel feed pipe to throttle body, lightly apply a coat of engine oil to O-ring.
d. Fill and bleed cooling system. Refer to Cooling System / Service and Repair / Cooling System Bleed. See: Cooling System/Service and
Repair
e. Adjust accelerator and kickdown cables and check for leakage at all fuel, vacuum and coolant connections.
