Removal and Replacement
Intake ManifoldREMOVAL
1. Remove the collector cover.
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 2.0 l (2.1 US qt, 1.8 Imp qt) of coolant.
9. Disconnect the connectors from exhaust oil flow control solenoid valve (A) and exhaust camshaft position sensor (B).
10. Disconnect the connectors from wastegate control solenoid valve, and remove the clip (A) which secure the engine harness.
11. Lower the vehicle.
12. Remove the air intake duct.
13. Remove the intercooler.
14. Disconnect the A/C pressure hoses from A/C compressor.
15. Disconnect the vacuum hose from the PCV valve.
16. Remove the bolts which secure the engine harness and PCV pipe to the intake manifold, and remove the intake duct from the throttle body.
17. Disconnect the preheater hose from throttle body.
18. Disconnect the brake booster vacuum hose.
19. Disconnect the vacuum hose from rocker cover.
20. Disconnect the vacuum hose from blow-by pipe, and remove the bolt securing the blow-by pipe to the intake manifold protector RH.
21. Disconnect vacuum hose (A) and vacuum control hose (B) from the PCV pipe.
22. Remove the nut securing the PCV pipe to the intake manifold protector RH, and move the PCV pipe in the forward direction of the vehicle.
23. Disconnect the bulkhead harness connector from the engine harness connector (brown).
24. Remove the bolt securing the bulkhead harness connector bracket, and disconnect the bulkhead harness connector from the engine harness connector (black).
25. Remove the engine harness connector from the engine rear hanger.
26. Disconnect the connectors from the engine coolant temperature sensor (A), oil pressure switch (B) and crankshaft position sensor (C).
27. Disconnect the connectors from front oxygen (A/F) sensor (A) and rear oxygen sensor (B).
28. Remove the clip which secure the generator cord to the intake manifold protector LH.
29. Disconnect the connector from the knock sensor.
30. Disconnect the connector from the intake camshaft position sensor.
31. Disconnect the connector from the intake oil flow control solenoid valve.
32. Disconnect the connector (A) from oil level switch.
33. Disconnect the connector (B) from ignition coil, and remove the clips (C) and bolt (D) securing the engine harness or oil level switch harness to the rocker cover.
34. Attach ST to the fuel delivery pipe and push ST in the direction of arrow mark to disconnect the fuel delivery hose.
ST 42099AE000 QUICK CONNECTOR RELEASE
CAUTION:
- Be careful not to spill fuel.
- Catch the fuel from hoses using a container or cloth.
35. Disconnect the fuel return hose using the ST.
ST 18371AA000 CONNECTOR REMOVER
CAUTION:
- Be careful not to spill fuel.
- Catch the fuel from hoses using a container or cloth.
1. Attach ST to the fuel return pipe as shown in the figure.
2. Insert the front side of ST into the quick connector.
3. Insert the back side of ST into the quick connector and push ST in the direction of arrow mark to disconnect the fuel return hose.
36. Remove the clip and disconnect the evaporation hose from the fuel pipe.
37. 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.
NOTE: If fuel hoses or clamps are damaged, replace them with new parts.
3. Connect the connector (A) from oil level switch.
4. Connect the connector (B) to ignition coil, and secure the engine harness or oil level switch harness to the rocker cover with clips (C) and bolt (D).
Tightening torque: 6.4 N.m (0.7 kgf.m, 4.7 ft.lb)
5. Connect the connector to the intake oil flow control solenoid valve.
6. Connect the connector to the intake camshaft position sensor.
7. Connect the connector to the knock sensor.
8. Secure the generator cord to the intake manifold protector LH with a clip.
9. Connect the connectors to front oxygen (A/F) sensor (A) and rear oxygen sensor (B).
10. Connect the connector to the engine coolant temperature sensor (A), oil pressure switch (B) and crankshaft position sensor (C).
11. Install the engine harness connector to the engine rear hanger.
12. Connect the bulkhead harness connector to the engine harness connector (black), and install the bolt securing the bulkhead harness connector bracket.
Tightening torque: 6.4 N.m (0.7 kgf.m, 4.7 ft.lb)
13. Connect the bulkhead harness connector to the engine harness connector (brown).
14. Install the nuts securing the PCV pipe to the intake manifold protector RH, and connect the vacuum hose (A) and vacuum control hose (B) to the PCV pipe.
Tightening torque: 6.4 N.m (0.7 kgf.m, 4.7 ft.lb)
15. Install the blow-by pipe to the intake manifold protector RH, and connect vacuum hose to the blow-by pipe.
Tightening torque: 6.4 N.m (0.7 kgf.m, 4.7 ft.lb)
16. Connect the vacuum hose to the rocker cover.
17. Connect the brake booster vacuum hose.
18. Connect the preheater hoses to the throttle body.
19. Install the intake duct to the throttle body, and install the bolts which secure the engine harness and PCV pipe to the intake manifold.
NOTE: When installing the intake duct to the throttle body, align the protrusion (a) on the intake duct to the installation position mark (b) on the throttle body to install.
Tightening torque:
T1: 3 N.m (0.3 kgf.m, 2.2 ft.lb)
T2: 6.4 N.m (0.7 kgf.m, 4.7 ft.lb)
20. Connect the vacuum hose to PCV valve.
21. Install the A/C pressure hoses to A/C compressor.
22. Install the intercooler.
23. Install the air intake duct.
24. Lift up the vehicle.
25. Connect the connectors to the wastegate control solenoid valve, and secure the engine harness with clip (A).
26. Connect the connectors to exhaust oil flow control solenoid valve (A) and exhaust camshaft position sensor (B).
27. Install the under cover.
28. Lower the vehicle.
29. Connect the battery ground terminal.
30. Fill engine coolant.
31. Charge the A/C system with refrigerant.
32. Install the collector cover.