For 1990-2009 cars

### Removal Procedure

Caution: Refer to Battery Disconnect Caution in the Preface section.

1. Disconnect the negative battery cable.
2. Remove the engine cover. Refer to Engine Cover Replacement .
3. Remove the charge air system hoses and ducts. Refer to Charge Air Cooler Inlet Pipe and Outlet Pipe Replacement .
4. Disconnect the radiator lower hose and drain coolant. Refer to Cooling System Draining and Filling .
5. Remove the accessory belt. Refer to Drive Belt Replacement .
6. Remove the fuel pipe-to-injection pump from the fuel injection pump.
7. Remove the power steering pump fastener and pull it left side.
8. Remove the coolant hose from intake manifold.
9. Remove the radiator upper hose.
10. Remove the injection pump return hose.
11. Remove the oil level indicator tube.
12. Remove the fuel pipe-to-common rail between common rail and fuel injection pump. Refer to Fuel Injector Fuel Feed Pipe Replacement .
13. Remove the wiring splice pack tightening bolt from intake manifold.
14. Remove the glow plug fuse box retaining bolts.
15. Remove the engine wiring.

15.1. | Disconnect the common rail pressure sensor connector.

15.2. | Disconnect the CTS connector.

15.3. | Disconnect the injection pump connector.

15.4. | Disconnect the generator connector.

15.5. | Disconnect the A/C compressor connector.

15.6. | Disconnect the starter solenoid wire connector.

15.7. | Disconnect the cooling fan connectors.

15.8. | Disconnect the T-MAP sensor connector

15.9. | Disconnect the CMP sensor connector.

15.10. | Disconnect the ETC body connector.

15.11. | Disconnect the common rail regulator connector.

16. Remove the engine wiring harness guide.
17. Remove the coolant by-pass hose.
18. Remove the EGR cooler outlet pipe.
19. Remove the intake manifold with the gasket.

### Installation Procedure

1. Install the intake manifold with a new gasket.

Notice: Refer to Fastener Notice in the Preface section.

2. Install the EGR cooler outlet pipe.

Tighten

• | Tighten the intake manifold bolts and nuts 23 N·m (17 lb ft).

• | Tighten the EGR cooler outlet pipe bolts and nuts 20 N·m (14.8 lb ft).

3. Install the engine wiring.
4. Install the glow plug fuse box retaining bolts.
5. Install the engine wiring splice pack tightening bolt to intake manifold.
6. Install the fuel pipe-to-common rail between common rail and fuel injection pump. Refer to Fuel Injector Fuel Feed Pipe Replacement .
7. Install the oil level indicator tube.
8. Install the power steering pump.
9. Install the fuel pipe-to-injection pump to the fuel injection pump.

Tighten

• | Tighten the glow plug fuse box bolts to 10 N·m (88.5 lb in).

• | Tighten the engine wiring splice pack tightening bolt to 15 N·m (11.1 lb ft).

• | Tighten the fuel pipe-to-common rail to 20 N·m (14.8 lb ft).

• | Tighten the fuel pipe-to-common rail retaining bolt to 10 N·m (88.5 lb in).

• | Tighten the oil level indicator tube bolts to 11 N·m (97.4 lb in).

• | Tighten the power steering pump bolts to 25 N·m (18.4 lb ft).

• | Tighten the fuel pipe-to-injection pump retaining bolt (to intake manifold) to 9 N·m (79.7 lb in).

• | Tighten the fuel pipe-to-injection pump retaining bolt to 25 N·m (18.4 lb ft).