INTAKE MANIFOLD
Fuel Injection (Fuel Systems)
3. Intake Manifold
S185034
(1)   Remove front side V-belt. <Ref. to ME(DOHC TURBO)-44, REMOVAL, V-belt.>
(2)   Disconnect the power steering switch connector.
A: REMOVAL
S185034A18
1)   Release fuel pressure. <Ref. to FU(DOHC TURBO)-50, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.>
2)   Disconnect battery ground cable.
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(3) Remove bolts which secure power steering pipe brackets to intake manifold.
NOTE:
Do not disconnect power steering hose.
3)   Lift up vehicle.
4)   Remove under cover.
5)   Drain coolant about 3.0 (3.2 US qt, 2.6 Imp qt).
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(4) Remove bolts which secure power steering pump.
6)   Remove air cleaner upper cover and air intake boot. <Ref. to IN(DOHC TURBO)-7, REMOVAL, Air Cleaner.>
7)   Remove air cleaner element.
8)   Remove intercooler. <Ref. to IN(DOHC TURBO)-10, REMOVAL, Intercooler.>
9)   Disconnect accelerator cable.
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10)   Remove coolant filler tank. <Ref. to CO-37, REMOVAL, Coolant Filler Tank.>
11)   Remove power steering pump from bracket.
FU(DOHC TURBO)-15
INTAKE MANIFOLD
Fuel Injection (Fuel Systems)
(5) Remove power steering tank from the 14) Disconnect brake booster hose, bracket by pulling it upward.
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15) Disconnect Pressure hose from intake duct.
(6) Place power steering pump on the right side wheel apron.
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16) Disconnect engine harness connectors from bulkhead harness connectors.
12) Disconnect emission hose from PCV valve.
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13) Disconnect engine coolant hoses from throttle body.
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FU(DOHC TURBO)-16
INTAKE MANIFOLD
Fuel Injection (Fuel Systems)
17) Disconnect connectors from engine coolant 21) Remove harness secured by clip (A) from the temperature sensor (A), oil pressure switch (B) and bracket, crankshaft position sensor (C).
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22) Disconnect fuel delivery hose, return hose and evaporation hose.
WARNING:
Catch fuel from hoses in a container.
18) Disconnect knock sensor connector.
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19) Disconnect connector from camshaft position sensor.
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23) Remove bolts which secure intake manifold to cylinder heads.
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20) Disconnect connector from ignition coil.
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24) Remove intake manifold.
B: INSTALLATION
S185034A11
1) Install intake manifold onto cylinder heads.
NOTE:
Always use new gaskets.
FU(DOHC TURBO)-17
INTAKE MANIFOLD
Fuel Injection (Fuel Systems)
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
5) Connect connector to camshaft position sensor.
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6) Connect connector to ignition coil.
2) Connect fuel delivery hose, return hose, and evaporation hose.
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7) Secure harness to the bracket with clip (A).
3) Connect connector to oil pressure switch (B), crankshaft position sensor (C) and engine coolant temperature sensor (A).
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4) Connect connector to knock sensor.
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FU(DOHC TURBO)-18
INTAKE MANIFOLD
Fuel Injection (Fuel Systems)
8) Connect engine harness connector to bulkhead 11) Connect emission hose to PCV valve, harness connectors.
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12) Connect pressure hose to intake duct.
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9) Connect brake booster vacuum hose.
13) Install power steering pump on bracket. (1) Install power steering tank on bracket.
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10) Connect engine coolant hoses to throttle body.
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(2) Connect connector to power steering pump switch.
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FU(DOHC TURBO)-19
INTAKE MANIFOLD
Fuel Injection (Fuel Systems)
(3) Install power steering pump, and tighten bolts.
Tightening torque:
20.1 Nm (2.05 kgf-m, 14.8 ft-lb)
19) Connect connector to fuel pump relay.
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20)  Connect battery ground cable.
21)   Lift up vehicle.
22)   Install under cover.
23)   Fill coolant. <Ref. to CO-14, FILLING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant. >
(4) Install power steering pipe brackets on right side intake manifold.
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(5) Install front side V-belt. <Ref. to ME(DOHC TURBO)-44, INSTALLATION, V-belt.>
14)   Install coolant filler tank. <Ref. to CO-37, INSTALLATION, Coolant Filler Tank.>
15)  Connect accelerator cable.
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16)   Install intercooler. <Ref. to IN(DOHC TURBO)-10, INSTALLATION, Intercooler.>
17)   Install air cleaner element.
18)   Install air cleaner upper cover and air intake duct as a unit. <Ref. to IN(DOHC TURBO)-7, INSTALLATION, Air Cleaner.>
FU(DOHC TURBO)-20
INTAKE MANIFOLD
Fuel Injection (Fuel Systems)
5) Remove throttle body from intake manifold.
C: DISASSEMBLY
S185034A06
1) Remove fuel pipe protector.
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6) Disconnect connector from fuel injector.
2) Remove engine ground terminal from intake manifold.
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7) Disconnect connector from tumble generator valve actuator.
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3)   Disconnect connector from throttle position sensor (A), idle air control solenoid valve (B) and pressure sensor (C).
4)  Separate engine harness secured to the intake manifold by clip (D).
8) Disconnect connector from tumble generator valve sensor.
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FU(DOHC TURBO)-21
INTAKE MANIFOLD
Fuel Injection (Fuel Systems)
9) Disconnect connector from purge control sole- 13) Remove two bolts which hold fuel pipes on the noid valve.                                                                         left side of intake manifold.
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10) Remove purge control solenoid valve.
14) Remove bolt which hold fuel injector pipe onto intake manifold. LH SIDE
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11) Disconnect evaporation hose from intake manifold.
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12) Disconnect evaporation hoses from purge valve.
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FU(DOHC TURBO)-22
INTAKE MANIFOLD
Fuel Injection (Fuel Systems)
RH SIDE
18) Loosen clamp which holds front left side fuel hose to injector pipe and remove the pipe from clamp.
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19)   Remove fuel injector pipe LH.
20)   Remove bolts which installs fuel pipe on intake manifold.
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15) Remove fuel injector.
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21)   Remove fuel pipe assembly and pressure regulator, from intake manifold.
22)   Remove intake duct from intake manifold.
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16) Remove harness bracket which hold engine harness onto intake manifold.
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17) Remove engine harness from intake manifold.
FU(DOHC TURBO)-23
INTAKE MANIFOLD
Fuel Injection (Fuel Systems)
23) Remove tumble generator valve assembly from intake manifold.
3) Install fuel pipe assembly and pressure regulator, to intake manifold.
Tightening torque:
5 Nm (0.51 kgf-m, 3.69 ft-lb)
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D: ASSEMBLY
S185034A02
NOTE:
Replace gasket with a new one.
1) Install tumble generator valve assembly to intake manifold.
Tightening torque:
8.25 Nm (0.84 kgf-m, 6.08 ft-lb)
4)   Install fuel injector pipe LH.
5)  Connect left side fuel hose to injector pipe, and tighten clamp screw.
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6)   Install engine harness to intake manifold.
7)   Install harness bracket which hold engine harness onto intake manifold.
Tightening torque:
19 Nm (1.94 kgf-m, 14.0 ft-lb)
2) Install air intake duct to intake manifold.
Tightening torque:
19 Nm (1.94 kgf-m, 14.0 ft-lb)
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FU(DOHC TURBO)-24
INTAKE MANIFOLD
Fuel Injection (Fuel Systems)
8) Install fuel injector.
RH SIDE
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9) Tighten bolt which install fuel injector pipe onto intake manifold.
Tightening torque:
19 Nm (1.94 kgf-m, 14.0 ft-lb)
LH SIDE
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10) Tighten two bolts which install fuel pipes on the left side of intake manifold.
Tightening torque:
5 Nm (0.51 kgf-m, 3.69 ft-lb)
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FU(DOHC TURBO)-25
INTAKE MANIFOLD
Fuel Injection (Fuel Systems)
11) Connect evaporation hoses to purge valve.
CAUTION:
Carefully connect the evaporation hoses.
13) Install purge control solenoid valve.
Tightening torque:
16 Nm (0.16 kgf-m, 1.2 ft-lb)
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14) Connect hoses to purge control solenoid valve.
CAUTION:
Carefully connect the evaporation hoses.
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(A)
To
fuel pipe ASSY
(B)
To
intake
duct
(C)
To
purge
control solenoid valve
(D)
To
intake
manifold
12) Connect evaporation hose to intake manifold.
(A)    To intake manifold
(B)    To purge valve
15) Connect connector to purge control solenoid valve.
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FU(DOHC TURBO)-26
INTAKE MANIFOLD
Fuel Injection (Fuel Systems)
16) Connect connector to tumble generator valve sensor.
19) Install throttle body to intake manifold.
NOTE:
Replace gasket with a new one.
Tightening torque:
22 Nm (2.2 kgf-m, 16 ft-lb)
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17) Connect connector to tumble generator valve actuator.
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20)  Connect connector to throttle position sensor (A), idle air control solenoid valve (B) and pressure sensor (C).
21)  Secure engine harness to the intake manifold with clip (D).
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18) Connect connector to fuel injector.
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22) Install engine ground terminal to intake manifold.
Tightening torque:
19 Nm (1.94 kgf-m, 14.0 ft-lb)
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FU(DOHC TURBO)-27
INTAKE MANIFOLD
Fuel Injection (Fuel Systems)
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23) Install fuel pipe protector.
Tightening torque:
19 Nm (1.94 kgf-m, 14.0 ft-lb)
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E: INSPECTION
S185034A10
Make sure the fuel pipe and fuel hoses are not cracked and that connections are tight.
FU(DOHC TURBO)-28