Removal and Replacement

Intake Manifold (Part 1):

Intake Manifold (Part 2):

Intake Manifold

REMOVAL
1. Set the vehicle on a lift.
2. Release the fuel pressure.
3. Remove the collector cover.




4. Disconnect the ground cable from battery.
5. Open the fuel filler flap lid, and remove the fuel filler cap.
6. Lift the vehicle.
7. Remove the under cover.
8. Drain approximately 3.0 Ohms (3.2 US qt, 2.6 Imp qt) of coolant.
9. Remove the intake duct from the air cleaner case.
10. Remove the intercooler.
11. Remove the generator.
12. Remove the coolant filler tank.







13. Disconnect the emission hose (A) and the connector (B) from the PCV hose assembly.




14. Remove the bolts which secure the air by-pass pipe and PCV pipe to the intake manifold, and loosen the clamp which connects the throttle body and duct.
15. Remove the duct from the throttle body.




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




17. Disconnect the brake booster hose.




18. Fit the cut out in the ST with the protrusion on the clamp to unlock, and disconnect the PCV hose from the rocker cover.
ST 18353AA000 CLAMP PLIERS




19. Disconnect the engine harness connectors from the bulk head harness connector.




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




21. Disconnect the connector from power steering pump switch.




22. Disconnect the knock sensor connector.




23. Disconnect the connector from the secondary air combination valve.




24. Disconnect the connector from the camshaft position sensor.




25. Disconnect the connector from the oil flow control solenoid valve.




26. Disconnect the connector from ignition coil.




27. Remove the engine harness fixed by clip (A) from the rocker cover.
28. Attach ST to the fuel delivery pipe and push ST in the direction of arrow mark to disconnect the fuel delivery hose.
ST 42099AE000 CONNECTOR REMOVER






CAUTION:
- Be careful not to spill fuel.
- Catch the fuel from hoses using a container or cloth.

29. Disconnect the fuel return hose using the ST. ST 18371AA000 CONNECTOR REMOVER

CAUTION:
- Be careful not to spill fuel.
- Catch the fuel from hoses using a container or cloth.




1. Attach the ST to the fuel return pipe as shown in the figure.




2. Insert the front side of ST into the quick connector.




3. Insert the back side of ST into the quick connector and push ST in the direction of arrow mark to disconnect the fuel return hose.




30. Remove the clip and disconnect the evaporation hose from the fuel pipe.




31. Remove the bolts which hold the tumble generator valve assembly onto the cylinder head.
32. Remove the intake manifold.

INSTALLATION
1. Install the intake manifold onto cylinder heads.

NOTE: Use a new gasket.






Tightening torque: 25 N.m (2.5 kgf-m, 18 ft-lb)

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






NOTE: If fuel hoses or clamps are damaged, replace them with new parts.

3. Tighten the hose clamp screw.

Tightening torque: 1.25 N.m (0.13 kgf-m, 0.94 ft-lb)




4. Connect the connector to the oil flow control solenoid valve.




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




6. Connect the connector to the knock sensor.




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




8. Connect the connectors to camshaft position sensor.




9. Connect the connector to the secondary air combination valve.




10. Connect the connector to the ignition coil.




11. Install the engine harness with clip (A) to the rocker cover.




12. Connect the engine harness connectors to the bulkhead harness connectors.




13. Connect the brake booster hose.
14. Connect the PCV hose to the rocker cover and lock it by fitting the clamp protrusion using ST.
ST 18353AA000 CLAMP PLIERS






NOTE: Use a new clamp.




15. Connect the engine coolant hoses to throttle body.
16. Install the duct to the throttle body.
17. Attach the bolts which secure the air by-pass pipe and PCV pipe to the intake manifold.






Tightening torque: 6.5 N.m (0.66 kgf-m, 4.8 ft-lb)




18. Connect the emission hose (A) and the connector (B) to the PCV hose assembly.




19. Install the coolant filler tank.
20. Install the intercooler.
21. Install the intake duct to the air cleaner case.
22. Install the fuse of fuel pump to the main fuse box.
23. Connect the battery ground cable to the battery.
24. Lift the vehicle.
25. Install the under cover.
26. Fill engine coolant.
27. Install the collector cover.