Removal and Replacement
Intake ManifoldREMOVAL
1. Remove the V-belt covers.
2. Collect the refrigerant from A/C system.
3. Release the fuel pressure.
4. Disconnect the ground cable from battery.
5. Open the fuel filler lid and remove the fuel filler cap.
6. Lift up the vehicle.
7. Remove the under cover.
8. Drain approximately 3.0 l (3.2 US qt, 2.6 Imp qt) of coolant.
9. Remove the air intake duct.
10. Remove the air intake boot.
11. Remove the intercooler.
12. Remove the generator.
13. Remove the coolant filler tank.
14. Disconnect the A/C pressure hoses from A/C compressor.
15. Disconnect the vacuum hose (A) from the PCV hose assembly and the PCV hose assembly connector (B) from the intake duct.
16. Disconnect the engine coolant hose from throttle body.
17. Disconnect the brake booster vacuum hose (A) and pressure regulator vacuum hose (B) from the intake manifold.
18. Disconnect the air control hose (A) from the waste gate actuator, and loosen the clamp which holds the intake duct to the turbocharger.
19. Disconnect the bulkhead harness connectors from the engine harness connectors.
20. Remove the engine harness connector from the engine harness bracket.
21. Disconnect the connector (A) from the engine coolant temperature sensor, connector (B) from the oil pressure switch, and connector (C) from the crankshaft position sensor.
22. Disconnect the connector from power steering pump switch.
23. Disconnect the connector from the knock sensor.
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. Lift up the vehicle.
28. Remove the engine harness cover. (right side only.)
29. Disconnect connector (A) from the exhaust camshaft position sensor, connector (B) from the exhaust oil flow control solenoid valve, and connector (C) from the ignition coil.
30. Lower the vehicle.
31. Remove the clip (A) which hold the engine harness to the rocker cover RH.
32. Remove the bolts that secure the air duct to the rocker cover LH, and remove the engine harness.
33. Disconnect the fuel delivery hose, fuel return hose and evaporation hose.
CAUTION:
- Be careful not to spill fuel.
- Catch the fuel from hoses using a container or cloth.
1. Set the ST to the fuel pipe.
ST 42099AE000 QUICK CONNECTOR RELEASE
2. Disconnect the quick connector of the fuel delivery hose and fuel return hose by pushing the ST in the direction of the arrow.
3. Remove the clip and disconnect the evaporation hose from the fuel pipe.
34. Remove the intake manifold from cylinder head.
INSTALLATION
1. Install the intake manifold onto cylinder heads.
NOTE: Use a new gasket.
Tightening torque: 25 N.m (2.5 kgf.m, 18.4 ft.lb)
2. Connect the fuel delivery hose, fuel return hose, and evaporation hose.
3. Fix the engine harness to the rocker cover LH with the air duct.
Tightening torque: 6.4 N.m (0.7 kgf.m, 4.7 ft.lb)
4. Fix the engine harness to the rocker cover RH with clips (A).
5. Lift up the vehicle.
6. Connect connector (A) to the exhaust camshaft position sensor, connector (B) to the exhaust oil flow control solenoid valve, connector (C) to the ignition coil.
7. Install the engine harness cover. (right side only.)
Tightening torque: 5 N.m (0.5 kgf.m, 3.7 ft.lb)
8. Lower the vehicle.
9. Connect the connector to the intake oil flow control solenoid valve.
10. Connect the connector to the intake camshaft position sensor.
11. Connect the connector to the secondary air combination valve.
12. Connect the connector to the knock sensor.
13. Connect the connector to the power steering pump switch.
14. Connect the connector (A) to the engine coolant temperature sensor, connector (B) to the oil pressure switch, and the connector (C) to the crankshaft position sensor.
15. Install the engine harness connector to engine harness bracket, then connect the bulkhead harness connector to the engine harness connector.
16. Connect the air control hose (A) to the wastegate actuator, and install the turbocharger to the intake duct.
Tightening torque: 3 N.m (0.3 kgf.m, 2.2 ft.lb)
17. Connect the brake booster vacuum hose (A) and pressure regulator vacuum hose (B) to the intake manifold.
18. Connect the engine coolant hoses to throttle body.
19. Connect the vacuum hose (A) to the PCV hose assembly and the PCV hose assembly connector (B) to the intake duct.
20. Install the A/C pressure hoses to A/C compressor.
21. Install the coolant filler tank.
22. Install the generator.
23. Install the intercooler.
24. Install the air intake boot.
Tightening torque: 2.5 N.m (0.3 kgf.m, 1.8 ft.lb)
25. Install the air intake duct.
26. Connect the battery ground terminal.
27. Lift up the vehicle.
28. Install the under cover.
29. Lower the vehicle.
30. Install the V-belt cover.
Tightening torque: 13 N.m (1.3 kgf.m, 9.6 ft.lb)
31. Fill engine coolant.
32. Charge the A/C system with refrigerant.