Removal and Installation

Intake Manifold (Part 1):

Intake Manifold (Part 2):

Intake Manifold

REMOVAL
1. Release the fuel pressure.
2. Open the fuel filler flap lid, and remove the fuel filler cap.
3. Remove the collector cover.




4. Disconnect the ground cable from battery.
5. Lift-up the vehicle.
6. Remove the under cover.
7. Drain the coolant about 3.0 L (3.2 US qt, 2.6 Imp qt).
8. Remove the intake duct from air cleaner case.
9. Remove the intercooler.
10. Remove the generator.
11. Remove the coolant filler tank.







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




13. Disconnect the engine coolant hose from throttle body.




14. Disconnect the brake booster hose.








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




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




17. Disconnect the knock sensor connector.




18. Disconnect the connector from camshaft position sensor.




19. Disconnect the connector from the oil flow control solenoid valve.




20. Disconnect the connector from ignition coil.




21. Disconnect the fuel delivery hose, return hose and evaporation hose.
1. Disconnect the connectors of fuel delivery line and return line by pushing the ST in the direction of arrow.
ST 42099AE000 CONNECTOR REMOVER
2. Remove the clip and disconnect the evaporation hose from pipe.

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




22. Remove the bolts which hold intake manifold onto the cylinder heads.
23. Remove the intake manifold.

INSTALLATION




1. Install the intake manifold onto cylinder heads.

NOTE: Use a new gasket.




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

NOTE: If fuel hoses or clamps are damaged, replace them with new ones.

3. Tighten the hose clamp screws.

Tightening torque: 1.25 N.m (0.13 kgf-m, 0.94 ft-lb)




4. Connect the connector to oil flow control solenoid valve.




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




6. Connect the connector to knock sensor.




7. Connect the connector to camshaft position sensor.




8. Connect the connector to ignition coil.







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




10. Connect the brake booster hose.




11. Connect the engine coolant hose to throttle body.







12. Connect the emission hose (A) and connector (B) to PCV hose assembly.
13. Install the coolant filler tank.
14. Install the intercooler.
15. Install the intake duct to air cleaner case.
16. Install the fuse of fuel pump to main fuse box.
17. Connect the battery ground cable to battery.
18. Lift-up the vehicle.
19. Install the under cover.
20. Fill with engine coolant.
21. Install the collector cover.