Removal and Installation (U5/Low Emissions)

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 cleaner case and air intake chamber.
5. Remove power steering pump and tank from brackets.
1. Remove air intake duct.
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.

6. Disconnect spark plug cords from spark plugs.




7. Disconnect PCV hose from intake manifold.




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




9. Disconnect brake booster hose.




10. Remove air intake chamber stay RH and engine harness bracket, and disconnect engine harness connectors from bulkhead harness connectors.




11. Disconnect knock sensor connector.




12. Disconnect connector from crankshaft position sensor.




13. Disconnect connector from oil pressure switch.




14. Disconnect connector from camshaft position sensor.




15. Disconnect connectors from front oxygen (A/F) sensor.




16. Disconnect connectors from engine coolant temperature sensor.




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




18. Using the ST, disconnect fuel hoses from fuel pipes.

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

ST 42099AE000 CONNECTOR REMOVER




19. 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.




2. Connect fuel hoses.




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




4. Connect connectors to engine coolant temperature sensor.




5. Connect connectors to front oxygen (A/F) sensor.




6. Connect connector to camshaft position sensor.




7. Connect connector to oil pressure switch.




8. Connect connector to crankshaft position sensor.




9. Connect knock sensor connector.




10. Install air intake chamber stay RH and engine harness bracket, and connect engine harness connectors to bulkhead connectors.




11. Connect brake booster hose.




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




13. Connect PCV hose to intake manifold.
14. Connect spark plug cords to spark plugs.
15. 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.




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

16. Install air cleaner case and air intake chamber.
17. Connect connector to fuel pump relay.




18. Connect battery ground cable.