Removal and Installation
INTAKE MANIFOLDREMOVAL
1) Release fuel pressure.
2) Disconnect connector from mass air flow sensor.
3) Loosen clamp which connects air intake duct to air intake chamber.
4) Remove two clips of air cleaner upper cover.
5) Disconnect blow-by hose from air intake duct.
6) Remove air intake duct and air cleaner upper cover as a unit.
7) Remove air cleaner element.
8) Loosen clamp which connects air intake chamber to throttle body.
9) Disconnect air hoses, and remove air intake chamber.
10) Disconnect accelerator cable (1).
11) Disconnect cruise control cable (2). (With cruise control model)
12) Disconnect vacuum hoses from pressure sources switching solenoid valve.
13) Remove power steering pump from bracket.
(1) Remove V-belt cover.
(2) Loosen lock bolt and slider bolt, and remove power steering pump drive V-belt.
(3) Remove bolts which secure power steering pipe brackets to intake manifold.
NOTE: Do not disconnect power steering hose.
(4) Remove bolts which install power steering pump.
(5) Place power steering pump on the right side wheel apron.
14) Disconnect spark plug cords from ignition coil.
15) Disconnect PCV hose from intake manifold.
16) Disconnect engine coolant hose from throttle body.
17) Disconnect engine coolant hose (1) from idle air control solenoid valve.
18) Disconnect air by-pass hose (2) from idle air control solenoid valve.
19) Disconnect brake booster hose.
20) Remove EGR pipe.
21) Disconnect canister hoses from pipes. (2500 cc, 2200 cc FWD and Taiwan spec. vehicles)
22) Disconnect engine harness connectors from bulk-head harness connectors, and remove engine harness connectors from bracket.
23) Disconnect connectors from engine coolant temperature sensor (1) and thermometer (2).
24) Disconnect knock sensor connector.
25) Disconnect connector from camshaft position sensor.
26) Disconnect connector from crankshaft position sensor.
27) Disconnect connector from oil pressure switch.
28) Disconnect fuel hoses from fuel pipes.
WARNING: CATCH FUEL FROM HOSES IN A CONTAINER.
29) Remove bolts which hold intake manifold onto cylinder heads.
30) Remove intake manifold.
INSTALLATION
1) Install intake manifold onto cylinder heads.
CAUTION: Always use new gaskets.
Tightening torque: 25 ± 2 Nm (2.5 ± 0.2 kg-m, 18.1 ± 1.4 ft-lb)
2) Connect fuel hoses.
3) Connect connector to oil pressure switch.
4) Connect connector to crankshaft position sensor.
5) Connect connector to camshaft position sensor.
6) Connect knock sensor connector.
7) Connect connectors to engine coolant temperature sensor (1) and thermometer (2).
8) Install engine harness connectors to bracket, and connect engine harness connectors to bulkhead connectors.
9) Connect canister hoses. (2500 cc, 2200 cc FWD and Taiwan spec. vehicles)
10) Install EGR pipe.
Tightening torque: 34 ± 2 Nm (3.5 ± 0.2 kg-m, 25.3 ± 7.4 ft-lb)
11) Connect brake booster hose.
12) Connect engine coolant hose (1) to idle air control solenoid valve.
13) Connect air by-pass hose (2) to idle air control solenoid valve.
14) Connect engine coolant hose to throttle body.
15) Connect PCV hose to intake manifold.
16) Connect spark plug cords to ignition coil.
17) Install power steering pump on bracket.
(1) Install power steering pump on bracket, and tighten bolts.
Tightening torque: 20.1 ± 2.5 Nm (2.05 ± 0.25 kg-m, 14.8 ± 1.8 ft-lb)
(2) Install power steering pipe brackets on right side intake manifold.
(3) Install power steering pump drive V-belt.
(4) Adjust V-belt.
(5) Install V-belt cover.
18) Connect vacuum hoses to pressure sources switching solenoid valve.
19) Connect accelerator cable (1).
20) Connect cruise control cable (2). (With cruise control model)
21) Install air intake chamber and connect air hoses.
Tightening torque: 4.9 ± 0.5 Nm (0.5 ± 0.05 kg-m, 3.6 ± 0.4 ft-lb)
22) Install air cleaner element.
23) Install air cleaner upper cover and air intake duct as a unit.
CAUTION: Before installing air cleaner upper cover, align holes with protruding portions of air cleaner lower case, then secure upper cover to lower case.
24) Connect connector to mass air flow sensor.