Removal and Replacement

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 spark plug cords from the spark plugs by pulling the plug caps. (Do not pull the cord.)
6. Disconnect the engine coolant hoses (A) from throttle body.






7. Disconnect the brake booster hose (A).






8. Disconnect the PCV hose (A) from intake manifold.
9. Disconnect the engine harness connectors (B) from bulkhead harness connectors.






10. Disconnect the connectors from the engine coolant temperature sensor.






11. Disconnect the knock sensor connector.






12. Disconnect the connector from crankshaft position sensor.






13. Disconnect the connector from power steering pump switch (A).
14. Disconnect the connector from the oil pressure switch (B).






15. Disconnect the connector from the camshaft position sensor.






16. Remove the EGR pipe from intake manifold.






17. Disconnect the following connector.
1. Front oxygen (A/F) sensor connector
2. Rear oxygen sensor connector
3. Engine harness connectors

18. 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.






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 hose and evaporation hose to the fuel pipe.

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

3. Install the EGR pipe to intake manifold.






4. Connect the following connectors.
1. Front oxygen (A/F) sensor connector
2. Rear oxygen sensor connector
3. Engine harness connectors

5. Connect the connectors to camshaft position sensor.






6. Connect the connector to the power steering pump switch (A).
7. Connect the connector to the oil pressure switch (B).






8. Connect the connector to crankshaft position sensor.






9. Connect the knock sensor connector.






10. Connect the connector to engine coolant temperature sensor.






11. Connect the PCV hose (A) to intake manifold.
12. Connect the engine harness connectors (B) to bulkhead harness connectors.






13. Connect the brake booster hose (A).






14. Connect the engine coolant hoses (A) to throttle body.






15. Connect the spark plug cords to spark plugs.
16. Install the generator.
17. Install the air intake duct, air cleaner case and air intake chamber.
18. Install the fuse of fuel pump relay to the main fuse box.
19. Connect the battery ground cable to battery.