Removal and Installation

Intake Manifold Part 1:

Intake Manifold Part 2:

REMOVAL

1. Release fuel pressure.
2. Open fuel flap lid, and remove fuel filler cap.




3. Disconnect battery ground cable.
4. Remove air intake duct and air cleaner case.
5. Disconnect accelerator cable (A).




6. Disconnect cruise control cable (B). (With cruise control model)
7. Remove power steering pump and tank from brackets.
1. Remove resonator chamber.
2. Remove front V-belt.




3. Remove bolts which hold power steering pipes onto intake manifold protector.

NOTE: Do not disconnect power steering hose.




4. Remove bolts which install power steering pump bracket.




5. Disconnect connector from power steering pump switch.




6. Remove power steering tank from the bracket by pulling it upwards.




7. Place power steering pump and tank on the right side wheel apron.

8. Disconnect spark plug cords from spark plugs.




9. Disconnect PCV hose from intake manifold.




10. Disconnect engine coolant hose (A) from throttle body.




11. Disconnect brake booster hose.




12. Remove air cleaner case stay RH and engine harness bracket, and disconnect engine harness connectors from bulkhead harness connectors.




13. Disconnect connectors from engine coolant temperature sensor.




14. Disconnect knock sensor connector.




15. Disconnect connector from crankshaft position sensor.




16. Disconnect connector from oil pressure switch.




17. Disconnect connector from camshaft position sensor.




18. Remove EGR pipe from intake manifold and cylinder head.




19. Disconnect fuel hoses from fuel pipes.

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




20. Remove bolts which hold intake manifold onto cylinder heads, and remove intake manifold.

INSTALLATION




1. Install 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 fuel hoses.




3. Install EGR pipe to intake manifold and cylinder head.

Tightening torque: 33 N.m (3.4 kgf-m, 24.6 ft-lb)




4. Connect connector to camshaft position sensor.




5. Connect connector to oil pressure switch.




6. Connect connector to crankshaft position sensor.




7. Connect knock sensor connector.




8. Connect connectors to engine coolant temperature sensor.




9. Install air cleaner case stay RH and engine harness bracket, and connect engine harness connectors to bulkhead connectors.




10. Connect brake booster hose.




11. Connect engine coolant hose (A) to throttle body.




12. Connect PCV hose to intake manifold.
13. Connect spark plug cords to spark plugs.
14. Install power steering pump and tank on brackets.




1. Install power steering tank on bracket.




2. Connect connector to power steering pump switch.




3. Tighten bolts which install power steering pump on bracket.

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




4. Install power steering pipes onto right side intake manifold protector.
5. Install front V-belt.




6. Install resonator chamber.

Tightening torque: 33 N.m (3.4 kgf-m, 24.6 ft-lb)

15. Connect accelerator control cable (A).




16. Connect cruise control cable (B). (With cruise control models)
17. Install air intake duct and air cleaner case.




18. Connect connector to fuel pump relay




19. Connect battery ground cable.

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