Removal and Installation

Intake Manifold Part 1:

Intake Manifold Part 2:

REMOVAL
1. Release the fuel pressure.
2. Open the fuel filler lid and remove the fuel filler cap.




3. Disconnect the battery ground cable.
4. Lift up the vehicle.
5. Remove the under cover.




6. Drain the coolant about 3.0 l (3.2 US qt, 2.6 Imp qt).
7. Remove the air cleaner upper cover and air intake boot.
8. Remove the air cleaner element.
9. Remove the intercooler.




10. Disconnect the accelerator cable.
11. Remove the coolant filler tank.
12. Remove the power steering pump.
1. Remove the front side V-belt.




2. Disconnect the power steering switch connector.
3. Remove the bolts which secure the power steering pipe brackets to the intake manifold.






NOTE: Do not disconnect the power steering hose.




4. Remove the bolts which secure the power steering pump bracket.




5. Remove the power steering tank from the bracket by pulling it upward.




6. Place the power steering pump on the right side wheel apron.




13. Disconnect the emission hose from the PCV valve.




14. Disconnect the engine coolant hoses from the throttle body.




15. Disconnect the brake booster hose.




16. Disconnect the pressure hose from the intake duct.







17. Disconnect the engine harness connectors from the bulkhead harness connectors.




18. Disconnect the connectors from the engine coolant temperature sensor (A), oil pressure switch (B) and crankshaft position sensor (C).




19. Disconnect the knock sensor connector.




20. Disconnect the connector from the camshaft position sensor.




21. Disconnect the connector from the ignition coil.




22. Disconnect the engine harness fixed by clip (A) from the bracket.
23. Disconnect the fuel delivery hose, return hose and evaporation hose.






CAUTION:
- Do not spill fuel.
- Catch fuel from hoses in a container or cloth.




24. Remove the bolts which secure the intake manifold to the cylinder heads.
25. Remove the intake manifold.

INSTALLATION




1. Install the intake manifold onto cylinder heads.

NOTE: Always use new gaskets.

Tightening torque: 25 N.m (2.5 kgf-m, 18.1 ft-lb)




2. Connect the fuel delivery hose, return hose, and evaporation hose.




3. Connect the connector to the oil pressure switch (B), crankshaft position sensor (C) and engine coolant temperature sensor (A).




4. Connect the connector to the knock sensor.




5. Connect the connector to the camshaft position sensor.




6. Connect the connector to the ignition coil.




7. Connect the engine harness with clip (A) to the bracket.







8. Connect the engine harness connector to the bulkhead harness connectors.




9. Connect the brake booster vacuum hose.




10. Connect the engine coolant hoses to the throttle body.




11. Connect the emission hose to the PCV valve.




12. Connect the pressure hose to the intake duct.
13. Install the power steering pump.




1. Install the power steering tank on the bracket.




2. Connect the connector to the power steering pump switch.




3. Install the power steering pump, and tighten the bolts.

Tightening torque: 22 N.m (2.2 kgf-m, 15.9 ft-lb)




4. Install the power steering pipe brackets on the right side intake manifold.
5. Install the front side V-belt.

14. Install the cooler filler tank.




15. Connect the accelerator cable.
16. Install the intercooler.
17. Install the air cleaner element.
18. Install the air cleaner upper cover and air intake duct as a unit.




19. Connect the connector to the fuel pump relay.
20. Connect the battery ground cable.
21. Lift up the vehicle.
22. Install the under cover.
23. Fill the coolant.

INSPECTION
Make sure the fuel pipe and fuel hoses are not cracked and that connections are tight.