Removal and Replacement

Intake Manifold

REMOVAL

1. Set the vehicle on a lift.
2. Release the fuel pressure.
3. Disconnect the ground cable from battery.






4. Open the fuel filler lid, and remove the fuel filler cap.
5. Lift up the vehicle.
6. Remove the under cover.
7. Drain approximately 3.0 l (3.2 US qt, 2.6 Imp qt) of coolant.
8. Remove the air intake duct and air intake chamber.
9. Remove the generator.
10. Disconnect the spark plug cord from the spark plug.
11. Disconnect the engine coolant hoses (A) from throttle body.






12. Disconnect the brake booster vacuum hose (A).






13. Disconnect the PCV hose (A) from intake manifold.






14. Remove the bolt, and disconnect the bulk head harness connector from the engine harness connector and rear engine hanger.






15. Slide the engine harness connector in the direction of the arrow and remove the rear engine hanger.






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






17. Disconnect the knock sensor connector.






18. Disconnect the connector from crankshaft position sensor.






19. Disconnect the connector from power steering pump switch (A).
20. Disconnect the connector from the oil pressure switch (B).






21. Disconnect the connector from the camshaft position sensor.






22. Disconnect the front oxygen (A/F) sensor connector (A) and rear oxygen sensor connector (B).






23. Disconnect the connector from the oil switching solenoid valve.
24. Disconnect the connector from the variable valve lift diagnosis oil pressure switch.

- LH side






- RH side






25. Disconnect the connector from the oil temperature sensor.






26. Remove the EGR pipe from intake manifold.






27. 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 QUICK CONNECTOR RELEASE

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.






28. Remove the bolts which secure intake manifold to cylinder head.






29. Remove the intake manifold.

INSTALLATION

1. Install the intake manifold onto cylinder heads.

NOTE: Use a new gasket.






2. Connect the fuel delivery 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 connector to the oil temperature sensor.






5. Connect the connector to the variable valve lift diagnosis oil pressure switch.

- LH side






- RH side






6. Connect the connector to the oil switching solenoid valve.
7. Connect the front oxygen (A/F) sensor connector (A) and rear oxygen sensor connector (B).






8. Connect the connectors to camshaft position sensor.






9. Connect the connector to the power steering pump switch (A).
10. Connect the connector to the oil pressure switch (B).






11. Connect the connector to crankshaft position sensor.






12. Connect the knock sensor connector.






13. Connect the connector to engine coolant temperature sensor.






14. Connect the PCV hose (A) to intake manifold.






15. Connect the brake booster hose (A).






16. Connect the engine harness connector to the bulkhead harness connector and fasten to the rear engine hanger with bolt.






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






18. Connect the spark plug cords to spark plugs.
19. Install the generator.
20. Install the air intake duct and air intake chamber.
21. Connect the ground cable to battery.






22. Lift up the vehicle.
23. Install the under cover.
24. Lower the vehicle.
25. Fill engine coolant.

INSPECTION

Make sure the fuel pipe and fuel hoses are not damaged and the connections are tightened firmly.