Removal and Replacement

Intake Manifold

REMOVAL
1. Release the fuel pressure.
2. Disconnect the ground cable from battery.






3. Open the fuel filler lid and remove the fuel filler cap.
4. Lift up the vehicle.
5. Remove the under cover RH.
6. Drain approximately 3.0 l (3.2 US qt, 2.6 Imp qt) of coolant.
7. Remove the air intake duct.
8. Remove the air intake chamber and intake boot.
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.






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






14. Remove the bolt, and disconnect the bulkhead 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 it from 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 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 oil temperature sensor.






26. Remove the EGR pipe from intake manifold.






27. Disconnect the fuel delivery hose and evaporation hose from fuel pipe.
1. Disconnect the quick connector of the fuel delivery 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.






28. 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 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.

Tightening torque: 34 N.m (3.5 kgf.m, 25.1 ft.lb)






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 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.






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

Tightening torque: 6.4 N.m (0.7 kgf.m, 4.7 ft.lb)






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






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






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