Removal and Installation

Intake Manifold Part 1:

Intake Manifold Part 2:

REMOVAL

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




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




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




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

NOTE: Do not disconnect the power steering hose.




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




5. Disconnect the connector from the power steering pump switch.




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




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

8. Disconnect the spark plug cords from the spark plugs.




9. Disconnect the PCV hose from the intake manifold.




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




11. Disconnect the brake booster hose.




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




13. Disconnect the connectors from the engine coolant temperature sensor.




14. Disconnect the knock sensor connector.




15. Disconnect the connector from the crankshaft position sensor.




16. Disconnect the connector from the oil pressure switch.




17. Disconnect the connector from the camshaft position sensor.




18. Disconnect the fuel hoses from the fuel pipes.

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




19. Remove the bolts which hold intake manifold onto the cylinder heads.
20. Remove the intake manifold.

INSTALLATION




1. Install the intake manifold onto the cylinder heads.

NOTE: Replace the gaskets with new ones.

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




2. Connect the fuel hoses.




3. Connect the connector to the camshaft position sensor.



4. Connect the connector to the oil pressure switch.




5. Connect the connector to the crankshaft position sensor.




6. Connect the knock sensor connector.




7. Connect the connectors to the engine coolant temperature sensor.




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




9. Connect the brake booster hose.




10. Connect the engine coolant hose (A) to the throttle body.




11. Connect the PCV hose to the intake manifold.
12. Connect the spark plug cords to the spark plugs.
13. Install the power steering pump and reservoir tank to bracket.




1. Install the reservoir tank to bracket.




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




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

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




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




6. Install the resonator chamber.

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

14. Connect the accelerator cable (A).




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




17. Connect the connector to the fuel pump relay.




18. Connect the battery ground cable to battery.

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