Removal and Replacement

INTAKE MANIFOLD

REMOVAL
1. Set the vehicle on a lift.
2. Remove the V-belt covers.






3. Remove the air intake duct.
4. Collect the refrigerant from the A/C system.
5. Release the fuel pressure.
6. Disconnect the ground cable from the battery.






7. Open the fuel filler lid, and remove the fuel filler cap.
8. Lift up the vehicle
9. Remove the under cover.
10. Drain approximately 3.0 l (3.2 US qt, 2.6 Imp qt) of coolant.
11. Remove the air intake boot.






12. Remove the intercooler.
13. Remove the generator.
14. Remove the coolant filler tank.
15. Disconnect the A/C pressure hoses from A/C compressor.
16. Disconnect the vacuum hose (A) from the PCV hose assembly and the PCV hose assembly connector (B) from the intake duct.






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






18. Disconnect the brake booster vacuum hose (A) and pressure regulator vacuum hose (B) from the intake manifold.






19. Disconnect the air control hose (A) from the waste gate actuator, and loosen the clamp which holds the turbocharger to the intake duct.






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






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






22. Disconnect the connector from power steering pump switch.






23. Disconnect the knock sensor connector.






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






25. Disconnect the connector from the intake camshaft position sensor.






26. Disconnect the connector from the intake oil flow control solenoid valve.






27. Remove the engine harness cover. (Right side only)






28. Disconnect the connectors from the exhaust camshaft position sensor (A), exhaust oil flow control solenoid valve (B), and ignition coil (C).






29. Remove the engine harness fixed by clip (A) from the rocker cover. (Right side only)






30. Remove the bolt and the engine harness holding the air duct. (Left side only)






31. Disconnect the fuel delivery hose, fuel return hose, and evaporation hose.
1. Disconnect the quick connector on the fuel delivery hose and fuel return hose by pushing the ST in the direction of the arrow.
ST 42099AE000 QUICK CONNECTOR RELEASE
2. Remove the clip and disconnect the evaporation hose from the fuel pipe.

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






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






33. Remove the intake manifold.

INSTALLATION

1. Install the intake manifold onto cylinder heads.

NOTE: Use a new gasket.






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






3. Fix the engine harness to the rocker cover with clips (A). (Right side only)






4. Fix the engine harness with the air duct. (Left side only)






5. Connect the connectors to the exhaust camshaft position sensor (A), exhaust oil flow control solenoid valve (B), and ignition coil (C).






6. Install the engine harness cover. (Right side only)






7. Connect the connector to the intake oil flow control solenoid valve.






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






9. Connect the connector to the knock sensor.






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






11. Connect the connector to the intake camshaft position sensor.






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






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






14. Connect the air control hose (A) to the waste gate actuator, and tighten the clamp which holds the turbocharger to the intake duct.






15. Connect the brake booster vacuum hose (A) and pressure regulator vacuum hose (B) to the intake manifold.






16. Connect the engine coolant hoses to throttle body.






17. Connect the vacuum hose (A) to the PCV hose assembly and the PCV hose assembly connector (B) to the intake duct.






18. Install the coolant filler tank.
19. Install the generator.
20. Install the intercooler.
21. Install the air intake boot.






22. Connect the ground cable to the battery.






23. Lift up the vehicle
24. Install the under cover.
25. Install the V-belt cover.






26. Install the air intake duct.
27. Fill engine coolant.
28. Charge the A/C system with refrigerant.