Removal and Installation
Intake Manifold Part 1:
Intake Manifold Part 2:
REMOVAL
1. Release fuel pressure.
2. Open fuel flap lid, and remove fuel filler cap.
3. Disconnect battery ground cable.
4. Remove air intake duct, air cleaner assembly and air intake chamber.
5. Disconnect accelerator cable (A).
6. Disconnect cruise control cable (B). (With cruise control model)
7. Remove power steering pump and tank from brackets.
1. Remove V-belt.
2. Remove power steering oil pipe with bracket.
3. Remove bolts which install power steering pump bracket.
NOTE: Do not separate hose and pipe from the main pump.
4. Disconnect power steering pump switch connector.
5. Remove power steering tank from the bracket by pulling it upward.
6. Place power steering pump on the right side wheel apron.
8. Remove two bolts which install washer tank on body.
9. Disconnect connector from front window washer motor.
10. Disconnect connector from rear gate glass washer motor.
11. Disconnect rear window glass washer hose from washer motor, then plug connection with a suitable cap.
12. Move washer tank upward.
13. Disconnect PCV hoses from cylinder head cover.
14. Disconnect engine coolant hose from throttle body.
15. Disconnect brake booster hose.
16. Remove EGR pipe from EGR valve.
NOTE: Be careful not to drop gaskets.
17. Disconnect engine harness connectors from bulkhead harness connectors.
18. Disconnect engine ground cable from intake manifold.
19. Disconnect fuel hoses from fuel pipes.
WARNING:
- Do not spill fuel.
- Catch fuel from hoses in a container or cloth.
20. Remove ground cable from fuel pipe protector LH.
21. Remove fuel pipe protector LH.
22. Disconnect air assist hose (A).
23. Remove the bolt (B), which holds fuel inject to pipe LH onto cylinder head.
24. Remove ground cable from fuel pipe protector RH.
25. Remove fuel pipe protector RH.
26. Disconnect air assist hose (A).
Remove the bolt (B), which holds fuel injector pipe RH onto cylinder head.
27. Remove bolts which holds intake manifold onto cylinder heads.
28. Remove intake manifold.
INSTALLATION
1. Install intake manifold onto cylinder heads.
CAUTION: Always use new gaskets.
Tightening Torque: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
2. Install the bolt (B), which holds fuel injector pipe RH onto cylinder head.
Tightening Torque: 19 Nm (1.9 kgf-m, 14 ft-lb)
3. Connect air assist hose (A).
4. Install fuel pipe protector RH.
Tightening Torque: 19 Nm (1.9 kgf-m, 14 ft-lb)
5. Install ground cable to fuel pipe protector RH.
6. Install the bolt (B) which holds fuel injector pipe RH onto cylinder head.
Tightening Torque: 19 Nm (1.9 kgf-m, 14 ft-lb)
7. Connect air assist hose (A).
8. Install fuel pipe protector LH.
Tightening Torque: 19 Nm (1.9 kgf-m 14 ft-lb)
9. Install ground cable to fuel pipe protector LH.
10. Install EGR pipe to EGR valve
CAUTION: Always use new gasket.
Tightening Torque: 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
11. Connect fuel hoses.
12. Connect engine ground cable to intake manifold.
13. Connect engine harness connectors to bulkhead connectors.
14. Connect brake booster hose.
15. Connect engine coolant hose to throttle body.
16. Connect PCV hose to cylinder head cover.
17. Install power steering pump and tank on brackets.
1. Install power steering tank on bracket.
2. Connect connector to power steering pump switch.
3. Tighten bolts which install power steering pump on bracket.
Tightening Torque: 20 Nm (2.0 kgf-m, 14 ft-lb)
4. Install power steering pipes with bracket.
5. Install V-belt.
18. Connect rear window washer hose to washer motor.
19. Connect front window washer motor connector.
20. Connect rear window washer motor connector.
21. Install washer tank on body.
22. Connect accelerator cable (A).
23. Connect cruise control cable (B). (With cruise control models)
24. Install air intake duct, air cleaner and air intake chamber.
25. Connect connector to fuel pump relay.
26. Connect battery ground cable.
INSPECTION
Make sure the fuel pipe and fuel hoses are not cracked and that connections are tight.