INTAKE MANIFOLD REMOVAL

PROCEDURE


  1. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY (for Type B)

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  2. REMOVE INTERCOOLER ASSEMBLY

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  3. REMOVE GENERATOR ASSEMBLY

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  4. REMOVE WINDSHIELD WIPER MOTOR ASSEMBLY

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  5. REMOVE SUSPENSION TOWER DAMPER (w/ Performance Rod)


    1. B008ICQ

      Remove the 2 nuts and suspension tower damper.

  6. REMOVE OUTER COWL TOP PANEL (for LHD)


    1. w/o Performance Damper:


      1. Disconnect the connector, 4 clamps and wire harness.

      2. Remove the 13 bolts, 2 nuts and outer cowl top panel.

        B008H9AC02
        B008IUL Connector B008H52 Bolt
        B008HTY Nut - -

    2. w/ Performance Rod:


      1. Disconnect the connector.

      2. Detach the 4 clamps and disconnect the wire harness.

      3. Remove the 13 bolts and outer cowl top panel.

        B008IX5C02
        B008IUL Connector B008H52 Bolt

  7. REMOVE OUTER COWL TOP PANEL (for RHD)


    1. w/o Performance Rod:


      1. Disconnect the connector.

      2. Detach the 4 clamps and disconnect the wire harness.

      3. Remove the 13 bolts, 2 nuts and outer cowl top panel.

        B008IHZC03
        B008IUL Connector B008H52 Bolt
        B008HTY Nut - -

    2. w/ Performance Rod:


      1. Disconnect the connector.

      2. Detach the 4 clamps and disconnect the wire harness.

      3. Remove the 13 bolts and outer cowl top panel.

        B008HX5C03
        B008IUL Connector B008H52 Bolt

  8. REMOVE PURGE VSV

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  9. DISCONNECT WATER BY-PASS HOSE


    1. B008H2F

      Slide the 2 clips and disconnect the No. 5 sub-radiator hose and No. 6 sub-radiator hose from the No. 2 water by-pass pipe.

  10. DISCONNECT ENGINE WIRE


    1. B008JAY

      Disconnect the 3 connectors and detach the wire harness clamp.

    2. Remove the bolt and nut from the wire harness bracket.

    3. B008HD2

      Remove the bolt, detach the wire harness clamp and disconnect the wire harness.

    4. B008I26

      Disconnect the 7 connectors and detach the 3 clamps.

    5. B008JIX

      Disconnect the 3 connectors, detach the 2 clamps and disconnect the engine wire.

    6. Remove the ground bolt.

  11. REMOVE NO. 2 WATER BY-PASS PIPE


    1. B008H0R

      Remove the 3 bolts and No. 2 water by-pass pipe from the cylinder head cover sub-assembly and No. 2 vacuum switching valve bracket.

  12. DISCONNECT NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY


    1. B008I3C

      Detach the clamp and disconnect the No. 2 vacuum transmitting hose assembly from the vacuum pump assembly and cylinder head cover sub-assembly.

  13. REMOVE NO. 2 TURBO PRESSURE SENSOR

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  14. REMOVE NO. 1 VACUUM TRANSMITTING HOSE


    1. B008HHX

      Detach the clamp and disconnect the No. 1 vacuum transmitting hose from the intake manifold.

  15. DISCONNECT VACUUM TRANSMITTING HOSE ASSEMBLY


    1. B008H1S

      Detach the 5 clamps and disconnect the vacuum transmitting hose assembly from the cylinder head cover sub-assembly.

    2. B008JJ5

      Disconnect the vacuum transmitting hose assembly from the waste gate valve actuator with bracket assembly.

  16. REMOVE NO. 2 PCV HOSE


    1. B008IZW

      Slide the 2 clamps and remove the No. 2 PCV hose from the intake manifold and cylinder head cover sub-assembly.

  17. DISCONNECT THROTTLE BODY WATER BY-PASS HOSE


    1. B008JIJC01
      *1 No. 1 Water By-pass Hose
      *2 No. 2 Water By-pass Hose

      Slide the clamp and disconnect the No. 2 water by-pass hose from the No. 1 water by-pass pipe.

    2. Slide the clamp and disconnect the No. 1 water by-pass hose from the cylinder head sub-assembly.

  18. REMOVE INTAKE MANIFOLD


    1. B008GNXC01
      *A for Type A
      *B for Type B

      Remove the bolt.

    2. B008GPY

      Remove the 3 bolts, 2 nuts and intake manifold.

    3. B008H68

      Remove the 2 nuts, No. 1 water by-pass hose and No. 2 water by-pass hose.

    4. B008GP1

      Remove the 2 bolts and intercooler support bracket sub-assembly.

      Note

      Align the intercooler support bracket sub-assembly with its marked original position and removal it.

    5. B008JN9

      Remove the bolt and bracket wire harness clamp bracket.

    6. B008H96

      Remove the 2 intake manifold gaskets from the intake manifold.

  19. REMOVE NO. 2 FUEL VAPOR FEED HOSE


    1. B008HL8

      Slide the clamp and remove the No. 2 fuel vapor feed hose from the intake manifold.

  20. REMOVE BRACKET


    1. B008J90

      Remove the bolt from the intake manifold.

  21. REMOVE NO. 3 VACUUM TRANSMITTING HOSE ASSEMBLY


    1. B008HU3

      Detach the 2 clamps.

    2. B008ISE

      Remove the No. 3 vacuum transmitting hose from the vacuum surge tank.

  22. REMOVE NO. 1 TURBO PRESSURE SENSOR


    1. B008ILQ

      Remove the bolt and No. 1 turbo pressure sensor.

  23. REMOVE VACUUM REGULATING VALVE ASSEMBLY

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  24. REMOVE NO. 4 VACUUM TRANSMITTING HOSE ASSEMBLY


    1. B008J70

      Detach the 2 clamps and remove the No. 4 vacuum transmitting hose assembly from the vacuum surge tank.

  25. REMOVE VACUUM SURGE TANK


    1. B008GRK

      Remove the 3 bolts and vacuum surge tank.