Do you have access to Mitchell1 Prodemand, or eautorepair.net DIY? If you are willing to share user/password (we can pay), please get in contact with us ASAP (truly, it is urgent): email operation-charm [[at]] tuta.io or click to submit anonymously
Removal and Installation
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 and air cleaner assembly.
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 resonator chamber.
2. Remove V-belt covers.
3. Loosen lock bolt and slider bolt, and remove power steering pump drive V-belt.
4. Remove bolts which secure power steering pipe brackets to intake manifold.
NOTE: Do not disconnect power steering hose.
5. Remove bolts which install power steering pump to bracket.
6. Place power steering pump on the right side wheel apron.
8. Disconnect spark plug cords from spark plugs.
9. Disconnect PV hose from intake manifold.
2200 cc Models / 2500 cc Models:
10. Disconnect engine coolant hose from throttle body.
11. Disconnect brake booster hose.
12. Remove air cleaner case stay RH and engine harness bracket, and disconnect engine harness connectors from bulkhead harness connectors.
13. Disconnect connectors from engine coolant temperature sensor.
14. Disconnect knock sensor connector.
15. Disconnect connector from crankshaft position sensor.
16. Disconnect connector from oil pressure switch.
17. Disconnect connector from camshaft position sensor.
18. Disconnect fuel hoses from fuel pipes.
WARNING:
- Do not spill fuel.
- Catch fuel from hoses in a container or cloth.
19. Remove bolts which hold intake manifold onto cylinder heads.
20. Remove intake manifold.
Installation
1. Install intake manifold onto cylinder heads.
CAUTION: Always use new gaskets.
Tightening torque:
25 ± 2 N.m (2.5 ± 0.2 kg.m 18.1 ± 1.4 ft.lb)
2. Connect fuel hoses.
3. Connect connector to camshaft position sensor.
4. Connect connector to oil pressure switch.
5. Connect connector to crankshaft position sensor.
6. Connect knock sensor connector.
7. Connect connectors to engine coolant temperature sensor.
8. Install air cleaner case stay RH and engine harness bracket, and connect engine harness connectors to bulkhead connectors.
9. Connect brake booster hose.
2500 cc Models:
10. Connect engine coolant hose to throttle body.
11. Connect PCV hose to intake manifold.
12. Connect spark plug cords to spark plugs.
13. Install power steering pump on bracket.
1. Tighten bolts which install power steering pump on bracket.
Tightening torque:
20.1 ± 2.5 N.m (2.05 ± 0.25 kg.m, 14.8 ± 1.8 ft.lb)
2. Install power steering pipe brackets on the right side of intake manifold.
3. Install power steering drive V-belt.
4. Adjust V-belt.
5. Install V-belt covers.
6. Install resonator chamber.
Tightening torque:
33 ± 10 N.m (3.4 ± 1.0 kg.m, 25 ± 7 ft.lb)
14. Connect accelerator cable (A).
15. Connect cruise control cable (B). (With cruise control models)
16. Install air intake duct and air cleaner assembly.
17. Connect connector to fuel pump relay.
18. Connect battery ground cable.