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