Removal and Installation
Intake Manifold (Part 1):
Intake Manifold (Part 2):
Intake Manifold
REMOVAL
1. Release the fuel pressure
2. Disconnect the ground cable from battery
3. Open the fuel filler flap lid, and remove the fuel filler cap
4. Remove the air intake duct, air cleaner case and air intake chamber
5. Remove the generator
6. Remove the power steering pump and reservoir tank from bracket
1. Remove the bolts which hold power steering pipes onto the protector
NOTE: Do not disconnect the power steering hose
2. Remove the bolts which install power steering pump bracket
3. Disconnect the connector (A) from the power steering pump switch
4. Remove the reservoir tank from the bracket by pulling it upwards
5. Place the power steering pump on the right side wheel apron
7. Disconnect the spark plug cords from spark plugs by pulling the plug cap. (Do not pull the cord)
8. Disconnect the engine coolant hoses (A) from throttle body
9. Disconnect the brake booster hose (A)
10. Disconnect the PCV hose (A) from intake manifold
11. Disconnect the engine harness connectors (B) from bulkhead harness connectors
12. Disconnect the connectors from engine coolant temperature sensor
13. Disconnect the knock sensor connector
14. Disconnect the connector from crankshaft position sensor
15. Disconnect the connector from oil pressure switch (A)
16. Disconnect the connector from camshaft position sensor
17. Remove the EGR pipe from intake manifold
18. Disconnect the fuel hoses from fuel pipes
1. Separate the quick connectors of fuel delivery line and return line by pushing the ST to the direction of arrow.
ST 42099AE000 CONNECTOR REMOVER
2. Remove the clip, and separate the evaporation hose from pipe
WARNING:
- Be careful not to spill fuel
- Catch the fuel from hoses using a container or cloth.
19. Remove the bolts which secure intake manifold to cylinder head
20. Remove the intake manifold.
INSTALLATION
1. Install the intake manifold onto cylinder heads.
NOTE: Use a new gasket.
2. Connect the fuel hoses and evaporation hose to fuel pipe.
NOTE: If hoses are damaged, replace them with new ones.
3. Install the EGR pipe to intake manifold.
4. Connect the connector to camshaft position sensor.
5. Connect the connector to oil pressure switch (A).
6. Connect the connector to crankshaft position sensor.
7. Connect the knock sensor connector.
8. Connect the connectors to engine coolant temperature sensor.
9. Connect the PCV hose (A) to intake manifold.
10. Connect the engine harness connectors (B) to bulkhead harness connectors.
11. Connect the brake booster hose (A).
12. Connect the engine coolant hoses (A) to throttle body.
13. Connect the spark plug cords to spark plugs.
14. Install the power steering pump and reservoir tank to bracket.
1. Install the reservoir tank to bracket.
2. Connect the connector (A) to the power steering pump switch.
3. Tighten the bolts which install power steering pump bracket.
4. Install the power steering pipes onto the right side intake manifold protector.
15. Install the generator.
16. Install the air intake duct, air cleaner case and air intake chamber.
17. Connect the connector to fuel pump relay.
18. Connect the battery ground cable to battery.