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.
6. Drain approximately 3.0 l (3.2 US qt, 2.6 Imp qt) of coolant.
7. Remove the clip (A) from the air intake boot.
8. Loosen the clamp (B) connecting the air intake boot and air cleaner case (rear).
9. Loosen the clamp (C) which connects the air intake boot and throttle body.






10. Remove the air intake boot from the throttle body, and move the air intake boot to the left side wheel apron.






11. Disconnect the preheater hose from throttle body.






12. Disconnect the connector (A) from the purge control solenoid valve.
13. Loosen the bolt (B) which secures the EGR pipe to the intake manifold.
14. Remove the nut (C) which holds EGR pipe from the water pipe assembly.






15. Disconnect the vacuum hose (A) from intake manifold.
16. Disconnect the connector (B) from manifold absolute pressure sensor.
17. Disconnect the connector (C) from the throttle position sensor.






18. Disconnect the brake booster vacuum hose from the intake manifold.






19. Disconnect the connector (A) from the mass air flow and intake air temperature sensor, and remove the clip (B) which holds the mass air flow and intake air temperature sensor harness.






20. Remove the air cleaner case (rear).






21. Remove the intake manifold protector RH.






22. Disconnect the fuel delivery pipe from the fuel pipe RH.

NOTE: Disconnect the quick connector as shown in the figure.










23. Remove the intake manifold protector LH.






24. Disconnect the fuel delivery pipe from the fuel pipe LH.

NOTE: Disconnect the quick connector as shown in the figure.










25. Disconnect the fuel delivery hose (A) and evaporation hose (B).

CAUTION:
- Be careful not to spill fuel.
- Catch the fuel from hoses using a container or cloth.

1. Attach ST to the fuel delivery pipe and push ST in the direction of arrow mark to disconnect the quick connector of the fuel delivery hose (A).
ST 42099AE000 QUICK CONNECTOR RELEASE
2. Remove the clip and disconnect the evaporation hose (B) from the evaporation pipe.






26. Remove the intake manifold from the tumble generator valve assembly.






27. Disconnect the connector from the engine, and then remove the engine harness.

NOTE: Refer to "COMPONENT" of "General Description" for how to disconnect the engine harness connectors.






INSTALLATION
1. Connect the connectors to the engine, and install the engine harness.

NOTE: Refer to "COMPONENT" of "General Description" for how to connect the engine harness connectors.

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






2. Install the intake manifold to the tumble generator valve assembly.

NOTE: Use a new gasket.

Tightening torque: 8.3 N.m (0.8 kgf-m, 6.1 ft-lb)






3. Connect the fuel delivery hose (A) and evaporation hose (B).






4. Connect the fuel delivery pipe to the fuel pipe LH.

CAUTION:
- Check that there is no damage or dust on the quick connector. If necessary, clean the seal surface of the pipe.
- When connecting the quick connector, make sure to insert the pipe all the way in before locking the slider.
- When it is difficult to lock the slider, check that the pipe is fully inserted.
- Make sure that the quick connector is securely connected.

NOTE: Connect the quick connector as shown in the figure.










5. Install the intake manifold protector LH.

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






6. Connect the fuel delivery pipe to the fuel pipe RH.

CAUTION:
- Check that there is no damage or dust on the quick connector. If necessary, clean the seal surface of the pipe.
- When connecting the quick connector, make sure to insert the pipe all the way in before locking the slider.
- When it is difficult to lock the slider, check that the pipe is fully inserted.
- Make sure that the quick connector is securely connected.

NOTE: Connect the quick connector as shown in the figure.










7. Install the intake manifold protector RH.

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






8. Install the air intake case (rear).






9. Install the clip (B) which secures the air flow and intake air temperature sensor harness, and connect the connector (A) to the air flow and intake air temperature sensor.






10. Connect the brake booster vacuum hose to the intake manifold.






11. Connect the vacuum hose (A) to the intake manifold.
12. Connect the connector (B) to the manifold absolute pressure sensor.
13. Connect the connector (C) to the throttle position sensor.






14. Connect the connector (A) to the purge control solenoid valve.
15. Tighten the nut (C) and bolt (B) which hold EGR pipe to the water pipe assembly.

NOTE:
- Use a new gasket.
- Always tighten the EGR pipe at (C) first, and then (B).

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






16. Install the preheater hose to the throttle body.






17. Install the air intake boot.
18. Lift up the vehicle.
19. Install the under cover.
20. Lower the vehicle.
21. Connect the battery ground terminal.






22. Fill engine coolant.