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 3.0 l (3.2 US qt, 2.6 Imp qt) of coolant.
9. Remove the air intake duct (rear) and air cleaner case.
10. Remove the intercooler.
11. Remove the generator.
12. Remove the coolant filler tank.
13. Disconnect the A/C pressure hoses from A/C compressor.
14. Disconnect the brake booster vacuum hose.
15. Remove the brake booster vacuum hose from the clip (A), and remove the bolts securing the air bypass pipe to the intake manifold.
16. Remove the bolts securing the PCV pipe assembly to the intake manifold, and remove the intake duct from the throttle body.
17. Disconnect the engine coolant hose from throttle body.
18. Disconnect the vacuum hose from nipple.
19. Disconnect the air control hose (A) from the waste gate actuator, and loosen the clamp which holds the intake duct to the turbocharger.
20. Disconnect the connector (A) from the PCV hose assembly A and the connector (B) from the knock sensor.
21. Disconnect the connector from the PCV hose assembly B and PCV hose assembly C.
22. Disconnect the bulkhead harness connectors from the engine harness connectors.
23. Remove the engine harness connector from the engine harness bracket.
24. 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.
25. Disconnect the connector from power steering pump switch.
26. Disconnect the connector from the secondary air combination valve.
27. Disconnect the connector from camshaft position sensor.
28. Disconnect the connector from the oil flow control solenoid valve.
29. Lift up the vehicle.
30. Disconnect the connector from ignition coil.
31. Lower the vehicle.
32. Disconnect the connector from the front oxygen (A/F) sensor, and remove the clip (A) and stay (B) which hold the engine harness to the rocker cover RH.
33. 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.
34. 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.
35. Remove the clip and disconnect the evaporation hose from the fuel pipe.
36. 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. Connect the front oxygen (A/F) sensor connector, and secure the engine harness to the rocker cover RH with clip (A) and stay (B).
Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
4. Lift up the vehicle.
5. Connect the connector to the ignition coil.
6. Lower the vehicle.
7. Connect the connector to oil flow control solenoid valve.
8. Connect the connectors to camshaft position sensor.
9. Connect the connector to the secondary air combination valve.
10. Connect the connector to the power steering pump switch.
11. 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.
12. Install the engine harness connector to engine harness bracket, then connect the bulkhead harness connector to the engine harness connector.
13. Connect the connector to the PCV hose assembly B and PCV hose assembly C.
14. Connect the connector (A) to the PCV hose assembly A and the connector (B) to the knock sensor.
15. 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)
16. Connect the vacuum hose to the nipple.
17. Connect the engine coolant hoses to throttle body.
18. Install the intake duct to the throttle body, and install the bolts which secure the PCV pipe assembly to the intake manifold.
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)
19. Install the bolts which secure the air bypass pipe to the intake manifold, and install the brake booster vacuum hose to the clip (A).
Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
20. Connect the brake booster vacuum hose.
21. Install the A/C pressure hoses to A/C compressor.
22. Install the coolant filler tank.
23. Install the generator.
24. Install the intercooler.
25. Install the air intake duct (rear) and air cleaner case.
25. Connect the battery ground terminal.
27. Lift up the vehicle.
28. Install the under cover.
29. Lower the vehicle.
30 Fill engine coolant.
31 Charge the A/C system with refrigerant.
32 Install the collector cover.