Removal and Replacement

Intake Manifold (Part 1):

Intake Manifold (Part 2):

Intake Manifold

Removal

1. Release the fuel pressure.
2. Disconnect the ground cable from battery.
3. Open the fuel filler flap lid and remove the fuel filler cap.
4. Lift up the vehicle.
5. Remove the under cover.




6. Drain the engine coolant about 3.0L (3.2 US qt, 2.6 Imp qt).
7. Remove the air cleaner upper cover and air intake boot.
8. Remove the air cleaner element.
9. Remove the intercooler.
10. Remove the coolant filler tank.
11. Remove the power steering pump.
^ Remove the front side V-belt.




^ Disconnect the power steering switch connector.




^ Remove the bolts which secure the power steering pipe brackets to the intake manifold.

NOTE: Do not disconnect the power steering hose.




^ Remove the bolts which secure the power steering pump bracket.




^ Remove the power steering tank from the bracket by pulling it upward.




^ Place the power steering pump on the right side wheel apron.




12. Disconnect the emission hose (A) and connector (B) from the PCV hose assembly.




13. Disconnect the engine coolant hoses from the throttle body.




14. Disconnect the brake booster vacuum hose.




15. Disconnect the pressure hose from the intake duct.




16. Disconnect the engine harness connectors from the bulkhead harness connectors.




17. Remove the engine harness connector from front harness connector.




18. Disconnect the connectors from the engine coolant temperature sensor (A), oil pressure switch (B) and crankshaft position sensor (C).




19. Disconnect the knock sensor connector.




20. Disconnect the connector from the camshaft position sensor.

21. Disconnect the connector from the ignition coil and ignitor assembly.




^ RH side




^ LH side

22. Disconnect the engine harness fixed by clip (A) from the rocker cover.




^ RH side




^ LH side




23. Using ST, disconnect fuel hoses from fuel pipes.

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

ST 42099AE000 CONNECTOR REMOVER





24. Remove the bolts which secure the intake manifold to the cylinder heads.
25. Remove the intake manifold.

Installation




1. Install the intake manifold onto cylinder heads.

NOTE: Always use new gaskets.




2. Connect the fuel delivery hose, return hose and evaporation hose.




3. Connect the connector to the oil pressure switch (B), crankshaft position sensor (C) and engine coolant temperature sensor (A).




4. Connect the connector to the knock sensor.




5. Connect the connector to the camshaft position sensor.

6. Connect the connector to the ignition coil and ignitor assembly.




^ RH side




^ LH side

7. Connect the engine harness with clip (A) to the rocker cover.




^ RH side




^ LH side




8. Connect the engine harness connector to front harness connector.




9. Connect the engine harness connector to the bulkhead harness connectors.




10. Connect the brake booster




11. Connect the engine coolant hoses to the throttle body.




12. Connect the emission hose (A) and connector (B) to the PCV hose assembly.




13. Connect the pressure hose to the intake duct.

14. Install the power steering pump.




^ Install the power steering tank on the bracket.




^ Connect the connector to the power steering pump switch.




^ Install the power steering pump, and tighten the bolts.




^ Install the power steering pipe brackets on the intake manifold RH.
^ Install the front side V-belt.

15. Install the coolant filler tank.
16. Install the intercooler.
17. Install the air cleaner element.
18. Install the air cleaner upper cover and air intake duct as a unit.




19. Connect the connector to the fuel pump relay.
20. Connect the battery ground cable to battery.
21. Lift up the vehicle.
22. Install the under cover.
23. Fill the engine coolant.