Removal and Replacement

Intake Manifold

REMOVAL

1. Set the vehicle on a lift.
2. Remove the collector cover.
3. Collect the refrigerant from A/C system.
4. Release the fuel pressure.
5. Remove the battery.
6. Open the fuel filler lid, and remove the fuel filler cap.
7. Lift up the vehicle.
8. Remove the under cover.
9. Drain approximately 3.0 l (3.2 US qt, 2.6 Imp qt) of coolant.
10. Remove the intake duct from the air cleaner case.
11. Remove the intercooler.
12. Remove the generator.
13. Remove the coolant filler tank.
14. Disconnect the A/C pressure hoses from A/C compressor.
15. Disconnect the vacuum hose (A) and the connector (B) from the PCV hose assembly.






16. Remove the connector from the PCV hose assembly.






17. Remove the bolts which secure the air by-pass pipe and PCV pipe to the intake manifold, and loosen the clamp which connects the throttle body and duct.






18. Remove the duct from the throttle body.
19. Disconnect the engine coolant hose from throttle body.






20. Disconnect the brake booster vacuum hose.






21. Disconnect the PCV hose from the rocker cover.

NOTE: Fit the cut out in the ST with the protrusion on the clamp as shown in the figure, unlock the clamp, and disconnect the PCV hose fastened by the clamp.

ST 18353AA000 CLAMP PLIERS






22. Disconnect the air control hose (A) from the wastegate actuator, and loosen the clamp that holds the turbocharger on the intake duct.






23. Disconnect the bulk head harness connectors from the engine harness connector.






24. Remove the engine harness connector from the engine harness bracket.

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






26. Disconnect the connector from power steering pump switch.






27. Disconnect the knock sensor connector.






28. Disconnect the connector from the secondary air combination valve.






29. Disconnect the connector from the camshaft position sensor.






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






31. Disconnect the air duct from the secondary air pump, and remove the bolts that install the air duct on the rocker cover LH.






32. Disconnect the connector from ignition coil.






33. Disconnect the connector from the front oxygen (A/F) sensor, and remove the engine harness fixed by clip (A) from the rocker cover. (right side only)






34. Attach ST to the fuel delivery pipe and push ST in the direction of arrow mark to disconnect the fuel delivery hose.

ST 42099AE000 QUICK CONNECTOR RELEASE

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






35. Disconnect the fuel return hose using the ST.

ST 18371AA000 CONNECTOR REMOVER

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

1. Attach ST to the fuel return pipe as shown in the figure.






2. Insert the front side of ST into the quick connector.






3. Insert the back side of ST into the quick connector and push ST in the direction of arrow mark to disconnect the fuel return hose.






36. Remove the clip and disconnect the evaporation hose from the fuel pipe.






37. Remove the bolts which hold the tumble generator valve assembly onto the cylinder head.






38. Remove the intake manifold.

INSTALLATION

1. Install the intake manifold onto cylinder heads.

NOTE: Use a new gasket.






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

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






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






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






5. Connect the connector to the knock sensor.






6. Connect the connector to the power steering pump switch.






7. Connect the connectors to camshaft position sensor.






8. Connect the connector to the secondary air combination valve.






9. Connect the connector from the front oxygen (A/ F) sensor, and install the engine harness with clip (A) to the rocker cover. (right side only)






10. Connect the connector to the ignition coil.






11. Connect the air duct to the secondary air pump, and install the air duct on the rocker cover.






12. Install the engine harness connector to engine harness bracket, then connect the bulkhead harness connector to the engine harness connector.






13. Connect the air control hose (A) to the wastegate actuator, and tighten the clamp that holds the intake duct on the turbocharger.






14. Connect the brake booster vacuum hose.






15. Connect the PCV hose to the rocker cover.

NOTE: Use a new clamp for the PCV hose clamp, fit the cut out in the ST with the protrusion on the clamp as shown in the figure, and lock the clamp.

ST 18353AA000 CLAMP PLIERS






16. Connect the engine coolant hoses to throttle body.






17. Install the duct to the throttle body.

Tightening torque: 3 N.m (0.3 kgf.m, 2.2 ft.lb)

18. Attach the bolts which secure the air by-pass pipe and PCV pipe to the intake manifold.






19. Attach the connector to the PCV hose assembly.






20. Connect the vacuum hose (A) and the connector B) to the PCV hose assembly.






21. Install the A/C pressure hoses.
22. Install the coolant filler tank.
23. Install the generator.
24. Install the intercooler.
25. Install the air intake duct and air cleaner case.
26. Install the battery.
27. Lift up the vehicle.
28. Install the under cover.
29. Install the under cover.
30. Fill engine coolant.
31. Charge the A/C system with refrigerant.
32. Install the collector cover.