Intake Manifold

Removal & Installation

2.0L DOHC Engine and 2.5L DOHC Engine

To Remove:

1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
2. Disconnect the ground cable from battery.
3. Open the fuel filler lid and remove the fuel filler cap.
4. Release the fuel pressure.

   Coolant Drain

5. Drain the engine coolant.
6. Remove or disconnect the following:
   • Under cover

     Air Cleaner assembly

   • Air cleaner upper cover
   • Air intake boot
   • Air cleaner element
   • Intercooler
   • Coolant filler tank
   • Power steering pump
   • Front side V-belt

     Power Steering Switch Connector

   • Power steering switch connector

     Power Steering Pipe Bracket

   • Power steering pipe bracket to intake manifold bolts

     Note: Do not disconnect the power steering hose.

     Power Steering Pump on Apron

   • Power steering pump bracket bolts (place the pump aside)
   • Power steering tank from the bracket by pulling it upward

     Emission Hose

   • Emission hose (A) and connector (B) from the PCV hose assembly
   • Engine coolant hoses from the throttle body

     Brake Booster Hose

   • Brake booster hose

     Pressure Hose From Intake

   • Pressure hose from the intake duct

     Engine Harness Connectors

   • Engine harness connectors from the bulkhead harness connectors

     Coolant temp, Oil Pressure, Crank Position Sensors

   • Engine coolant temperature sensor connector (A)
   • Oil pressure switch connector (B)
   • Crankshaft position sensor (C)

     Knock Sensor Connector

   • Knock sensor connector

     Camshaft Position Sensor

   • Camshaft position sensor connector

     Ignition Coil Connector

   • Ignition coil connector

     Engine Harness From Bracket

   • Engine harness fixed by clip (A) from the bracket

     Fuel Hoses

   • Fuel delivery hose, return hose and evaporation hose

     CAUTION
     Do not spill fuel. Catch fuel from hoses in a container or cloth.

     Intake Manifold Bolts

   • Intake manifold to cylinder head bolts

     Intake Exploded View

     Intake Exploded View Callouts

   • Intake manifold

To Install:

1. Install or connect the following:

   Note: Always use new gaskets.

   • Intake manifold onto cylinder heads
     1. Torque to: 18 ft. lbs. (25 Nm)

     Fuel Hoses

   • Fuel delivery hose
   • Return hose
   • Evaporation hose

     Coolant temp, Oil Pressure, Crank Position Sensors

   • Oil pressure switch (B) connector
   • Crankshaft position sensor (C) connector
   • Engine coolant temperature sensor (A) connector

     Knock Sensor Connector

   • Knock sensor connector

     Camshaft Position Sensor

   • Camshaft position sensor connector

     Ignition Coil Connector

   • Ignition coil connector

     Engine Harness From Bracket

   • Engine harness with clip (A) to the bracket

     Engine Harness Connectors

   • Engine harness connector to the bulkhead harness connectors

     Brake Booster Hose

   • Brake booster vacuum hose
   • Engine coolant hoses to the throttle body

     Emission Hose

   • Emission hose (A) and connector (B) to the PCV hose assembly
   • Pressure hose to the intake duct

     Power Steering Pipe Bracket

   • Power steering tank on the bracket
   • Power steering pump switch connector
   • Power steering pump, and tighten the bolts
     1. Torque to: 16 ft. lbs. (22 Nm)
   • Power steering pipe brackets on the intake manifold RH
   • Front side V-belt
   • Coolant filler tank
   • Intercooler (turbo)
   • Air cleaner element
   • Air cleaner upper cover
   • Air intake duct
   • Fuel pump relay connector
   • Battery ground cable to battery
   • Undercover
2. Fill the engine coolant

2.5L SOHC Engine

To Remove:

1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
2. Release fuel pressure.
3. Remove or disconnect the following:
   • Fuel filler cap
   • Battery ground cable
   • Air intake duct
   • Air cleaner case

   • Accelerator cable (1)
   • Cruise control cable (2)
   • Power steering pump and reservoir tank from bracket
   • Resonator chamber
   • Front side V-belt
   • Bolts connecting power steering pipes onto the intake manifold protector

     Note: Do not disconnect the power steering hose.

   • Bolts from power steering pump bracket
   • Power steering pump switch connector
   • Reservoir tank from the bracket and place the power steering pump aside
   • Spark plug cords from the spark plugs
   • PCV hose from the intake manifold

   • Engine coolant hoses (1) from the throttle body
   • Brake booster hose
   • RH air cleaner case stay and engine harness bracket
   • Engine harness connectors from the bulkhead harness connectors
   • Engine coolant temperature sensor connector
   • Knock sensor connector
   • Crankshaft position sensor connector
   • Oil pressure switch connector
   • Camshaft position sensor connector
   • Fuel hoses from the fuel lines
   • Bolts connecting intake manifold to cylinder heads
   • Intake manifold

To Install:

Note: Replace all gaskets with new ones.

1. Install or connect the following:
   • Intake manifold onto the cylinder heads
     1. Torque to: 18 ft. lbs. (25 Nm)
   • Fuel hoses
   • Connectors for camshaft position sensor,oil pressure switch, crankshaft position sensor, knock sensor, engine coolant temperature senso
   • RH air cleaner case stay and engine harness bracket
   • Engine harness connectors to the bulkhead connectors
   • Brake booster hose
   • Engine coolant hose to the throttle body
   • PCV hose to the intake manifold
   • Spark plug wires to the spark plugs
   • Power steering pump and reservoir tank to bracket
   • Reservoir tank to bracket
   • Connector to the power steering pump switch
   • Bolts which connect power steering pump bracket
     1. Torque to: 16 ft. lbs. (22 Nm)
   • Power steering lines onto the right side intake manifold protector
   • Front side V-belt
   • Resonator chamber
     1. Torque to: 24.6 ft. lbs. (33 Nm)
   • Accelerator cable
   • Cruise control cable
   • Air intake duct and air cleaner case
   • Connector to the fuel pump relay
   • Ground cable to battery